Accomplished mechanical engineer with experience designing, integrating and testing precision optical systems, spacerated hardware, and thermalvacuum chemical process chambers
*Cleanroom Design and Manufacturing
*CNC, Sheetmetal, Spinning, Die Forging
*Spacecraft Environmental Testing
*Precision Optical Alignment
*3D CAD and PDM tools
*Y14.41 ModelBase Definition
*Design of Experiments
*Transition to Production
*Design for Manufacturability
Engineering and Project Management Experience
Applied Materials – 2012 to Present
R&D Chamber Engineering Manager, Mar 2012 – Present
Senior engineer and project manager to develop highvolume next generation thermalvac wafer process chambers. System designs required class 100 cleanroom, chemical compatibility, thermal stability, process repeatability, and optimized cost of ownership. Responsible for full product lifecycle: design, prototype, manufacturing, integration, test, and support.
○ Evolve Next Gen Systems:
Developed the next generation preclean process chamber for metal deposition.
Maximized reuse of part for designs as a basis for scaling wafer processing equipment to exceed customer requirements on etch uniformity. Implemented innovative designs utilizing past design experience to assist in the integration, test and serviceability of the system. Performed GD&T analysis and DFx (cost, serviceability, reliability, manufacturing) on all designs. Managed design, procurement, integration, and test of the system in under 4 months. Coordinated multiple US and international subcontractor to develop manufacturing and quality processes. Validate units
against performance requirements with analysis and test. Identify product nonconformities, analyze root cause, develop and implement corrective action. Design details include 10e7torr base pressure, up to 30 torr throttling process pressure, 400C controllable heated pedestal with a 5C uniformity and stability, quartz plasma well, and various mechanical actuators for wafer movement and process surface placement.
○ Evolve Current Systems:
Design Engineering Manager for high priority customer project. Customer identified a critical
process gap that required selective, directional etch of dielectric material. The difficulty of the problem is due to the scale of the geometry moving past 10nm. Development of the system required collaboration between internal business units, US and international vendors, and multinational customers. Design details included multiple thermal control systems capable of 150C with a temperature uniformity of <1C, Fluorine compatible materials and seals, multiple
pressure controllable gas injection and vacuum control systems, multiple micron repeatable mechanisms, 1kV monopolar electrostatic chuck, and a multifrequency MHz RF delivery system. Parts consisted of CNC machined metals, ceramics, plastics, sheet metal, die forging, bonded, extruded, and various surface treatments. System was designed, procured, assembled, and integrated in under 6 months. Performed integration, test, and debugging at the customer facilities in Taiwan and Albany.
○ New Process Chamber Architecture:
Invented a new type of process chamber configuration designed to eliminate wafer cycle time on large batch, long cycle processes. This innovation has the potential to increase the overall tool
efficiency measured in wafers/time/area by 10% and facilitate using new composite substrates for flexible circuits.
○ Improve Engineering Efficiency:
Actively participated in defining ModelBased Definition for elimination of 2D drawing. The goal was to reduce the cycle type from concept to delivery by 50%, facilitating rapid product development
in a firsttomarket business environment.
Acretus – 2010 to Present
Systems Engineering Manager, Aug 2010 – Mar 2012
○ Established requirement and verification management process using JAMA Software. Formulated functional requirement specifications for aerospace projects. Established process for verification and validation. Generated and maintained verification tables for spacecraft subsystems. Developed automation script to generate verification matrices from functional requirements. Engineering manager responsible for making technical decisions on aerospace projects.
Managed multidisciplinary team.
Developed and maintained networking and computer infrastructure to support Windows and Linux clients. Built and maintained headless Linux server to maintain share folder, client system backup, collaboration services and video delivery. Built and maintained a ZFS managed JBOD cluster to support hardware redundancy and economic scaling.
BAE Systems – 2008 to 2010
Engineering Liaison, Enterprise Product Data Management, Oct 2008 – Apr 2010
Senior Technical Project Manager, Bradley Combat Systems, Jan 2008 – Feb 2009
○ Bradley Battle Command Vehicle:
Principal engineer for a team of 20 engineers to build, test, and deploy 4 Command and Control upgrade kits for the Bradley. The design goal was to develop an armoured communications
platform that could communicate on the move, house multiple communications networks and computer systems, operate in a 130F+ ambient environment, and run silently when required, without losing its defensive capabilities. Design details included 10 communication antennas including active tracking satellite, a comm rack with an array of servers, switches, inverters, and radio amplifiers, 150Ah of batteries, an auxiliary generator driven off the drivetrain, and
an A/C unit for equipment reliability. Upgrade kits were thoroughly tested in a surrogate environment in the US and installed insitu on actively deployed vehicles. Design kits were transitioned to production with minimal changes.
Lockheed Martin Space Systems – 1997 to 2008
Principal EngineerMechanical, Near Infrared Camera (NIRCam), Apr 2003 – Jan 2008
Lead Mass Properties Systems Engineer, Sep 1997 – Jan 2008
As a principle engineer, I was responsible for the systems design and integration of all primary cameras, stray light baffling, fold mirrors, optical system interfaces, and harnessing. Managed critical budgets including all mechanical, coefficient of thermal expansion, stray light, volume, and mass properties. Collaborated on a detailed Structure, Thermal, Optical, Performance (STOP) analysis, and closely worked with optical engineers, stray light engineers, and thermal engineers to meet difficult mission requirements. Design highlights of the camera mounts included 1 micron
repeatability at 37K, high electrical and low thermal isolation, integrated cosmic radiation shielding, and a 6dof solid alignment shim. Design details of the stray light baffling included individual covers to facilitate integration and test, active N2 for contamination control, hermetic electrical feedthroughs, 1e10W/mm stray light contamination, and low radiative coupling with adjacent instruments. Designs included brazed and welded titanium sheet metal baffling; forged extra low
interstitial titanium camera mounts; custom bolts designed for precision alignment, minimal stray light contribution, and multiple cryocycles; kinematic bipod mounts for launch loads and CTE neutral positioning. Verified DFx with full scale stereolithography model including mechanism simulators. Validated optical triplet design using LabView program to measure realtime relative optical element motion during cryocycle.
○ Gravity Probe-B:
Led verification team for detailed mass properties tests, static balance and dynamic balance of
Gravity Probe B. Analyzed and optimized designs to meet critical performance requirements for launch and onorbit environments. Audited solid model and BOM to ensure accuracy of mass properties prediction. Managed all systems mass and power budgets, and negotiated all mass properties related ICDs with launch partners and NASA. Developed detailed statistical mass properties models. Reduced prediction uncertainty by measured deployable components with
laser trackers, photogrammetry, and precision mass properties measurements. Performed optical alignment of the spacecraft to spin axis within 2 micron and 1 arcsec. Wrote software in C++ to automate mass properties optimization during the spin balance.
○ Research and Development
: Successfully predicted the mass properties of over 20 satellites and 15 satellite instruments, currently onorbit. Managed the mass properties team for LMSS’ research and development campus. Performed trade studies to optimize materials, vendors, packaging configurations and manufacturing. Developed software tools and refined processes to exploit new solid modeling systems for mass properties engineering.
MS, Aerospace Engineering, 2006, SJSU | BS, Mechanical Engineering, 1997, SCU
AS, Mechanical Drafting, 1994, RCC | Project Management Professional (PMP), 2014
Alison Nordt, Michael Jacoby, Brent Biggs, Todd Kvamme, Ted Cahoon, "NIRCam fold mirror and mount designs", SPIE Proceedings Vol. 6692, 2007 Cryogenic Optical Systems and Instruments XII
Brent Biggs, “Mass Properties using Statistical Techniques”, San Jose State University, April 2005
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