2. Portfolio Contents
• Space Application
• Military Aerospace
• Military
• Marine
• Automotive
• Commercial Aerospace
• Sporting Goods
• Patents
• Resume
3. Military Aerospace
• B2 Spirit Flight Control Rods
– Table rolled prepreg tubes,
tape wrap cured and
cylindrically ground with
secondarily bonded and
riveted Titanium T Rod
Inserts.
– Responsible for initial
process development.
– Advanced Composite
Products 1994
4. Military Aerospace
• B2 Spirit Bomb Bay Door
Torque Tubes
– Extremely high torque loads I
was responsible for the yearly
production manufacture of
this product for 6 years.
– Advanced Composite
Products
5. Military Aerospace
• UAV Tail Booms
– Carbon/Epoxy Tubes
– Responsible for:
• Primary Customer point of
contact
• Process Development and
documentation
• Production oversight
– Advanced Composite
Products 1994 • Searcher
• Pioneer
6. Military
• Talon MkVIIe Laser Range
Finder.
– Project Engineer for this
program.
– Unique Composite assembly
capable of hermetic seal
better than 5.2 X10-5 cc
helium per second.
– Responsibilities:
• Process development
• Mold and Fixture design
• All process documentation
• Primary customer point of
contact
– Awarded a flight simulator trip
by AAR Corporate for
outstanding achievement.
– AAR Composites 2006
7. Military
• RCA Phase Array Radar Unit .
– One of Several Manufacturing
Engineers for this program.
– Sub Component fabrication,
secondary bonding and
hardware installation.
– Advanced Composite
Products 1987
8. Military
• Folding Temporary Road
Surface. (SBIR program)
– One of Two Manufacturing
Engineers for this program.
– Filament Wound
Thermoplastic Matrix
Composite Structure. These
Panels were compression
molded in a custom designed
shuttling press.
– Designed Kreel holder and
fiber placement mechanism
for filament winder, Assisted
in the design and fabrication
of the consolidation press and
managed production of these
components.
– Advanced Composite
Products 1987-1992
9. Marine
• Rowing Shells
– Contract Position to launch new line of
boats and to streamline the existing
production process.
– Increased production by 50% in six
months with the introduction of a JIT
subcomponent assembly line
approach.
– Trained technicians to use new high
performance adhesives and
fabrication processes.
– Vespoli USA 1995
Note: The rowing shell shown on the right won
the gold in the 2000 Olympics.
• Vespoli USA 8 Man
Rowing Shell
10. Automotive
• Camper Top
– Responsible for the
development of the
polyurethane formulation and
preforming method used to
mold this product. See
patents
– Part of a 6 engineer team
responsible for the setup of a
100,000 sq.ft facility in New
Stanton PA that produced
150 camper tops per day.
– Corner stone product for
Advance USA’s Strata
Composites process
– Advance USA 1996-2000 • Fleetwood Coleman Pop-
up Camper Top
11. Automotive
• Freightliner Fold Down
Bunk.
– Strata Composite Product
development from
inception to production
launch.
– Responsibilities included
process development and
product testing.
– Designed an injection
defuser to distribute the
polyurethane and
maintain a uniform foam
density in the finished
product.
– Named as inventor on 2
US Patents
– Advance USA 1996-2000
12. Automotive
• Ford Tonneau Cover .
– GE Plastics, Ford, Advance
USA and Dow Chemical
teamed for a 5 year NIST
funded effort to introduce the
Strata Composites to the
Automotive Industry.
– Responsible for process
development and testing
– Achieved a 5 minute cycle time
for the production of this
product.
– Setup and operation of capitol
equipment.
– Development of UV curing
equipment used to bond
substrate materials.
– Advance USA 1996-2000
13. Commercial Aerospace
• Pratt & Whitney Global
Services
– Subcontracted from MTU Aero
engines as a Repair
Development Engineer.
– Document repair procedures
for turbine engines working
with Pratt & Whitney level III
engineers and DER’s.
– Responsible for all internal
composite engine components
as well as Fan Case, Fan
Blades and external
components such as the
engine fan cowl, trans cowl
and nozzle.
– Named as inventor on a
patent for a repair procedure.
– MTU Aero Engines 2005-2006
14. Commercial Aerospace
• Counter MANPAD Fairings
• Commercial Aircraft Counter
Measures System.
– Project Engineer.
• Management of Engineering
Team responsible for the
fabrication of the fairings for this
program.
• Prepreg Carbon Composite
Construction.
– AAR Composites 2007
15. Commercial Aerospace
• Aircraft Interiors
– Fabrication of composite and
decorative plexiglass pieces
for business jet interiors.
• Tooling design and
fabrication of headliner,
window panels, valence
panel, side ledge and heated
floor panels as well as all
decorative plexiglass
features.
• Process development
• Oversight of Installation in
Aircraft
Pictures shown are of several
Dassualt Falcon 20 interiors
– Jet Aviation 1981-1983
16. Commercial Aerospace
• Aircraft Seating
– Seat Designer
• Arm rests and Head
Rests
– Manager of the test
facility static and
dynamic testing as well
as the prototype shop.
• Supervision of 10
technician team
• Test sled scheduling
– BE Aerospace 2001
17. Commercial Aerospace
• Cessna CJ4 Fairings.
– Senior Project Engineer.
• Management of
Engineering Team
responsible for the
fabrication of the
fairings for this
program.
• VARTM and RTM
Carbon Composite
Construction
– AAR Composites 2008
18. Sporting Goods
• Bicycle Components
– Spinergy Bicycle wheel
• Project Engineer
responsible for
optimization and day to
day production of this
product.
• 25000 units shipped in
6 months
– Cannondale Mountain
Bike Swing Arm
• 1 of 2 Engineers
responsible for product
design and
development.
• RTM tool fabrication
process which was
later patented by Dow
UT on another
program
– Dow UT 1994-1995
19. Patents
• United States Patent 6,627,018O'Neill , et al. September 30, 2003 System and method of
forming composite structures
• Abstract
• A system and method for forming a composite structure involves providing at least two
polymeric sheets as outer layers such that a cavity is formed therebetween, adhesively
bonding fibrous layers to the polymeric layers to hold the fibrous layers in place during
processing, and injecting into the cavity a polymeric core material capable of exhibiting a
foamed character and a resinous character. The cavity is evacuated during filling with the
core material, and a blowing agent of the core material is activated upon exposure to the
evacuated cavity. The core material contacting the fibrous layers is reconverted to its
resinous character and forms a relative dense, resinous interface between the core and
fibrous layers. Upon filling the region of the cavity between the fibrous layers, a catalytic
reaction is initiated in the core. Then, each resinous interface is driven through the respective
fibrous layer to impregnate the fibrous layer and form a dense, resinous layer between each
fibrous layer and adjacent polymeric layer. A structural insert, such as a rigid plate adapted
to receive fasteners, is embedded within the core material for attaching other devices or
structures thereto.
• Inventors: O'Neill; Michael A. (Stonington, CT); Kirk; Wayne D. (Old Lyme, CT); Simmons;
Stuart C. (North Branford, CT); Trudeau; Paul (Old Lyme, CT); Bremmer; Jonathan W.
(Portland, CT) Assignee:Advance USA, LLC (Old Lyme, CT) Appl. No.: 690660Filed:
October 17, 2000Current U.S. Class:156/78 ; 156/245; 156/267; 156/275.3; 156/275.7;
156/291; 264/101; 264/257; 264/46.5; 264/46.8; 264/511; 264/54Field of Search:
156/77,78,267,245,275.3,275.7,291,285 264/54,46.5,46.8,101,257,514
20. Patents Continued
• United States Patent 6,331,028O'Neill , et al. December 18, 2001 Fiber-reinforced
composite structure
• Abstract
• A fiber-reinforced composite structure has two molded outer polymeric layers spaced apart
from each other and defining a cavity therebetween. Each molded outer polymeric layer
defines a sealing surface extending about a periphery of the respective layer, and the
opposing sealing surfaces cooperate to define a hermetic seal extending about a periphery
of the cavity. One or more multi-directional fiber reinforcement layers are adhesively attached
in a discontinuous manner to each outer polymeric layer, and define a first region of the
cavity extending between each respective outer polymeric layer and adjacent fiber
reinforcement layer, and a second region of the cavity extending between the fiber
reinforcement layers. A core is located between the two outer polymeric layers, and is made
of a resinous core material capable of exhibiting a foamed character and a resinous
character. The resinous core material has a blowing agent activatable upon exposure to a
predetermined vacuum pressure within the cavity to convert the core material within the
second region of the cavity from a resinous character to a foamed character and thereby fill
the second region of the cavity with the foamed core material. Each multi-directional fiber
reinforcement layer is impregnated with the core material exhibiting a relatively dense,
resinous character, and each first region of the cavity is substantially filled with the core
material exhibiting a resinous character to fixedly secure the multi-directional fiber
reinforcement layers to the outer polymeric layers. A structural insert, such as a rigid plate
adapted to receive fasteners, is embedded within the core material for attaching other
devices or structures thereto.
• Inventors: O'Neill; Michael A. (Stonington, CT); Kirk; Wayne D. (Old Lyme, CT); Simmons;
Stuart C. (North Branford, CT); Trudeau; Paul (Old Lyme, CT); Bremmer; Jonathan W.
(Portland, CT) Assignee:Advance USA, Inc. (Old Lyme, CT) Appl. No.: 690338Filed: October
17, 2000Current U.S. Class:296/100.01 ; 296/100.02; 428/71Field of Search:
296/100,100.01,160.02 428/71
21. Patents Continued
• United States Patent Application 20080060752
• Kind Code A1 Bogue; William F. ; et al. March 13, 2008
• Rebonding a metallized fabric to an underlying layer
• Abstract
• A method and system for repairing an insulation blanket having a metallized fabric that
becomes disbanded from an underlying layer of the insulation blanket. The method
includes cutting a first slit in the metallized fabric near a disbanded portion of the fabric,
inserting a repair material through the first slit such that the repair material is between
the disbanded portion of the fabric and the underlying layer, and adhering the
disbonded fabric and the underlying layer to the repair material to restore the
functionality of the metallized fabric.
• Inventors: Bogue; William F.; (Hebron, CT) ; Simmons; Stuart; (Northford, CT)
Correspondence Name and Address:
• KINNEY & LANGE, P.A.
• THE KINNEY & LANGE BUILDING, 312 SOUTH THIRD STREET MINNEAPOLIS
MN 55415-1002
• USAssignee Name and Adress:
• United Technologies Corporation
Hartford
CT Serial No.: 517769
• Series Code: 11
• Filed: September 8, 2006
