1. Project Portfolio
www.kalepa-tech.com
kalepa
tech
Sustainability
Consulting and Strategy

2. LIFE CYCLE ENGINEERING AND
SUSTAINABILITY

3. kalepa
tech
Sustainability
Consulting and Strategy
DIRECTOR OF SUSTAINABILITY SERVICES
SUSTAINABLE MINDS
Sustainable Minds, a Web-based Life Cycle Assessment (LCA) Software, designed to make
screening LCA results accessible and understandable for the non-LCA expert. As a startup,
Sustainable Minds runs a lean organization with key
players serving multiple functions within the organization.
I provide the following:
 Organizational strategy for sales and marketing
 Fill managerial roles
 Generate content for web, training and marketing
 Write articles
 Business development
 Frame and implement
consulting projects
 provided content and
 Develop and deliver training
 Participate in speaking
engagements.

4. kalepa
tech
Sustainability
Consulting and Strategy
ELECTRONICS EVALUATION FOR SUSTAINABILITY
A top manufacturer of electronic devices set a goal to become one of the greenest technology
companies in the world by proactively implementing green and sustainable practices. This
project investigated practices for product development and manufacturing cycles.
This effort focused on information gathering and investigation to define
common practices and tools for product development and
manufacturing cycles.
During this I completed the following activities:
 Develop preliminary mechanical parameters for
material substitutions
 Preliminary single screening LCA to compare
Alternatives for a selected subsystems.
 Investigation and comparison of sustainable and
green practices of competitors.
#1 #2
#4#3

5. kalepa
tech
Sustainability
Consulting and Strategy
MOBILE PHONE DESIGN STRATEGY
This case study examines ecological impacts and equivalent CO2 emissions for mobile phone
components, assemblies and life cycle phases to determine if 'eco-friendly' practices offer
impact reductions. While ‘eco-friendly’ practices offer reductions in ecological impacts, they do
not significantly reduce equivalent CO2 emissions relative to phones not marketed as ‘eco-
friendly’. Furthermore, it appears the most effective ‘eco-friendly’ practice is to reduce power
consumption.
Significant Results:
 recycled plastic housings reduces ecological impacts up to 50%
 recycling offers 66% reduction in ecological impacts
 Recycled packaging and instructions scenarios result in more
than 90% reductions in
equivalent CO2 emissions
 use-phase ecological
impacts and equivalent
CO2 emissions overshadow
all others.

6. kalepa
tech
Sustainability
Consulting and Strategy
LIQUID VS. BAR SOAP – ENVIRONMENTAL COMPARISON
100% Palm Oil
100% Animal Fat
100% Coconut Oil
50% Palm / 50% Coconut
50% Palm / 50% Animal
Figure 1 – Mid-point comparison of bar soap recipes
Waste
Manufacturing
Transport
Packaging
Figure 6 – Damage assessment for liquid soap manufacturing phases.
Many everyday choices offer opportunities to make small improvements in personal
sustainability while involving no additional effort or cost to implement. One such everyday
product consumers interact with multiple times a day is soap used for handwashing. The
following study takes a closer look at the environmental performance two types of hand soap
alternatives – bar soap and liquid soap.
Significant finding from this study:
 The ecological intensity of the liquid
soap ingredients is higher due to
larger volumes.
 ‘Best choice’ of product is largely
dependent on the user’s interaction
with the product.
 It is less about the product used and
more about the amount of warm water
used.

7. kalepa
tech
Sustainability
Consulting and Strategy
WELCOME TO OUT OF THE BOTTLE
A NEW TYPE OF NEIGHBORHOOD APOTHECARY
ONE
Provide quality beauty products by sourcing the finest ingredients,
environmentally progressive brands and repurposed materials.
TWO
Minimize our impact on the environment through the practices of
restoration, respect, reduction, reuse and recovery or the 5 R’s outlined
by o2 International Network for Sustainable Design.
OUR MISSION – TWO SIMPLE GOALS
R1 – RESTORE
Through collaboration with
supplier, we are dedicated to
restoring the environment
by sourcing products and
ingredients that are
sustainably harvested or
encourage environmental
regeneration
R2 - RESPECT
From the source of our
ingredients to the hands of
our customers and
everyone in-between, we
strive to ensure the well-
being of every person who
touches our products.
R3 – REDUCE
With the cooperation of our
ingredient and brand
suppliers, we aim to
minimize the superfluous
materials that enter our
store so that we can supply
our customers with only
what they use – quality
beauty products.
R4 – REUSE
Along with minimizing,
materials used are
repurposed and recycled
whether through
coordinating with our
suppliers or our customers,
we are dedicated to using
materials to the maximum
of their life.
R5 – RECOVER
For us, Recycling isn’t just
about taking back material
and using it again, it is
about returning material
back to nature. When
disposables are needed,
we source these materials
to be biodegradable.
5 R’s - OUR PHILOSOPHY
STEP INSIDE AND SEE HOW WE DO IT     

8. kalepa
tech
Sustainability
Consulting and Strategy
POST CYCLE COMMUTER COMPANY CONCEPT
USING WASTE TO CREATE BIOGAS ELECTRICITY

9. PROJECT MANAGEMENT

10. kalepa
tech
Sustainability
Consulting and Strategy
INTEGRATED HOSPITAL BED/BED PAN CONCEPT
CONCEPT GENERATION
This client is developing a new product for the medical industry with the goal of alleviating the
difficulty and embarrassment associated with providing a bedpan to a bed ridden patient. The
project was to develop a new product that would allow a bed ridden patient to use the toilet
comfortably, safely and easily while remaining in the hospital bed. Ultimately, this would be
done with minimal or without any assistance of a health care professional or caregiver.
Several concepts were generated and evaluated for feasibility.
Preliminary prototypes were developed and initial mechanism
explored. These devices were used to explore feasibility with
user focus groups and caregivers. The concepts are currently
under review for additional IP and FDA compliance.

11. kalepa
tech
Sustainability
Consulting and Strategy
A reactive gas processing equipment manufacturer
developed a technology that exceeded performance
expectations resulting in an immediate demand.
The prototype design was unable to meet this
demand or the projected sales price.
I managed this fast-paced, 3-month redesign project
that ultimately met the following criteria:
 Material cost reduction of 30%
 Reliability improvement including shipping
shock and vibration.
 50% reduction of assembly labor time
 Exceeding thermal & structural performance
 Complete manufacturing documentation.
 New technology implementation
 Vendor coordination for cost and timeline.
 Performance mapping, life testing,
reliability testing and FMEA.
ELECTRONIC CHASSIS RE-DESIGN
Original Design
New Design
New Design,
With frame

12. kalepa
tech
Sustainability
Consulting and Strategy
DOWNHOLE MEASUREMENTS TOOL
CAPACITIVE SENSOR DESIGN FOR IN-SITU MEASUREMENT
An oilfield technology company that designs electromechanical tools to characterize an oilwell
while drilling. This project was to innovative ways to characterize weight, torque, vibration, shock
and temperature. Sixteen concepts were presented; the top four were investigated. US and
international patents were awarded for these concepts.
The desired measurement is derived by measuring strain in a drilling tool. Historically, load cell
assemblies achieved accuracies of +/-2Klbs with the limitation of gauge fatigue, measurement
drift and frequent re-zeroing a dynamic environment with +20ksi pressures and +400 °F
temperatures.
This effort evaluated non-contact sensors to improve manufacturability, performance and life
compared to current and other concept designs. A capacitive displacement sensor system was
implemented as shown. Testing showed the following significant improvements
in gain, hysteresis, mechanical cross-talk and noise. However, the thermal
cross-talk was difficult to characterize.
Sensor
Plug
Target Plug
Mud Flow
Passage
Test SectionPressure
Adaptors

13. kalepa
tech
Sustainability
Consulting and Strategy
DOWNHOLE POWER ADAPTOR TOOL DESIGN
DIVISION OF FORMATION EVALUATION
A Standard Power Cartridge provides low voltage power to a power bus and is limited the top
of an toolstring. Resistive power dissipation reduces low-voltage output in long tool strings.
This power adaptor is an optional module to convert power supplies at alternative locations.
The tool is the first module to meet 1999 Environmental Qualifications including
 10,000 500g shocks
 Shipping vibration
 -20 to 200°C Thermal Cycles
 200°C long term high temperature life.
The tool shown was featured in the following press release
Groundbreaking MDT run for Shell in GOM.
The largest and most complex MDT string ever, was run
for Shell in GOM late August. . . which was made possible
using the MRBA booster module. . . also the heaviest toolstring
ever run. . . This result was far better then the success
criteria set by Shell. . . .
“. . . It was successful, set several "world firsts" records, and
Performed wIthout a problem.”, Rick Stocker, Shell.

14. RESEARCH, CONCEPT
GENERATION, PROTOTYPING

15. kalepa
tech
Sustainability
Consulting and Strategy
QUIET HIGH PERFORMANCE HAIR DRYER DESIGN
TECHNICAL ANALYSIS, TESTING AND CONCEPT GENERATION
A consumer products company wanted to generate and evaluate concepts for a quieter and higher
performing hair dryer compared he performance of products on the market. Patent Application
20100064542
Following evaluation, a target product specification was
developed and a preliminary prototypes was built to evaluate
noise reduction strategies In parallel with this effort, a new
turbine/fan design was under development.
Concepts and technologies that proved promising from
prototyping resulted in SLA conceptual prototypes. This
design incorporate innovative housing design, strategic
placement of damping material, improved intake design, flow
Conditioning and turbine design.

16. kalepa
tech
Sustainability
Consulting and Strategy
WATER RECREATION EQUIPMENT DESIGN
A client developing water recreational equipment wanted a product for traveling on water
using leg power. The first phase of the project evaluated the feasibility of the concept
through the evaluation of hull design, power requirements, human capabilities and
dynamics of canoe paddling.
Phase II generated several concepts sketches and small-scale prototypes. From
prototyping, calculations, analysis and design risk evaluation, it was determined the best
candidate for development was the elliptical stroke machine.
The final two phases of this project developed first a full size prototype to
prove the concept then design and develop a pre-production prototype.
The preproduction prototype reached speeds of 2.5mph under an average effort and
up to 4mph under a sprint effort.

17. kalepa
tech
Sustainability
Consulting and Strategy
INNOVATIVE FLUID PURIFIER DESIGN
RESEARCH AND CONCEPT GENERATION
A small appliance manufacturer of was seeking an innovative technology for purifying fluids.
They were interested in evaluating new technologies and technologies from alternative
industries. Phase 1 research included:
 Understanding contaminants their human impacts
 Methods to eliminate or render harmless contaminates.
 Competitive technologies
 Technologies and intellectual property use for air purification
My team generated hundreds of concepts for eliminating
or rendering harmless contaminates. Each concept was
evaluated on merit and several new product concepts
were generated and the client is currently in the process
of partnering with another industry on development.

18. kalepa
tech
Sustainability
Consulting and Strategy
METHODS TO MEASURE ATHLETIC PERFORMANCE
MODELING, ANALYSIS AND CONCEPT GENERATION
An athletic equipment company wanted to provide feedback to athletes on performance by
evaluating loads on athletic equipment to provide athletic performance. I generated
measurement concepts and evaluated feasibility through hand calculations, prototyping and
finite element analysis.
I also generated packaging concepts and project plans for the development and initial
manufacturing of an associated device. A development schedule from concept to production
was provided and preliminary designs around proposed electronics architecture

19. ENGINEERING

20. kalepa
tech
Sustainability
Consulting and Strategy
ELECTRONIC CHASSIS THERMAL DESIGN
COLD PLATE MODEL FOR COOLING POWER MOSFETS
Baseline analysis
Surface Tmax = 78.9C (matches well with test data)
Maximum Ferrite Temperature
Vary Copper Plate Thickness
0.080
0.125
0.094
0.100
65
66
67
68
69
70
71
72
73
74
75
0.07 0.08 0.09 0.1 0.11 0.12 0.13
Copper Thickness (in)
MaximumFerriteTemperature(degC)
Final design analysis for cooling MOSFETS and
Tmax,MOSFET = 65.3C and Tmax,DIODE= 72.4C.
A parametric study of cooling the power transformers to evaluate heat sink geometries, fluid cooling and
speed options.

21. kalepa
tech
Sustainability
Consulting and Strategy
SOLID STATE ELECTRONICS EVALUATION
RESEARCH, ANALYSIS AND CONCEPT GENERATION
Thermal management for high powered solid state devices is important in increasing the life
of the device. Thermal analysis generated models and alternative layouts to minimize junction
temperature and maximize duty cycle using only natural convection. Two-dimensional hand
calculations, material selection evaluation and layout alternatives were evaluated
Two analytical studies evaluated layout configurations and designs.
.
Thermal FEA
Studies
Natural Convection
CFD Studies
Through Thickness Temperature Distribution
Current Design (2D Paper Study Model)
96.784
98.379
96.841
99.353
127.853
50
62
74
86
98
110
122
134
146
158
170
0 0.5 1 1.5 2 2.5 3 3.5
Thickness (in)
Temperature(°C)
Heat Sink
Base
Spreader
Substrate
LED package

22. kalepa
tech
Sustainability
Consulting and Strategy
20,000 CFM WINDTUNNEL DESIGN
Lytron Inc designs industrial heat management solutions. A 30kW oil to air heat exchanger,
required a new wind tunnel for test and validation. As laboratory and test equipment
manager, I designed sensor and control system, specified the heating and cooling system
and aided in the wind tunnel design.
The sensor system included:
 2 Venturi Tubes with 0.25% accuracy
 3 differential pressure gauges
 Four absolute pressure gauges
 18 thermocouples
 Two Coriolis liquid flow meters
The sensors system was integrated with a data
acquisition system run on a LabVIEW platform.
User interface design and test stand validation
achieved a 98% heat transfer balance during
transients and near perfect balances during
steady state.
A full press release about the wind tunnel design
can be viewed at :
www.lytron.de/about/press_releases/2006_02_wind_tunnel.aspx

23. kalepa
tech
Sustainability
Consulting and Strategy
INFLATABLE DOWNHOLE SEAL DESIGN
DIVISION OF FORMATION EVALUATION, RAPID RESPONSE
New inflation packer elements were developed to withstand temperatures above 285°F
in mud. Previous attempts to extend operating range were
unsuccessful. I led this project as an active collaboration
between two suppliers and two product centers to develop
the an improved packer design.
Project Objectives:
 Increase temperature rating in stages.
 Develop reliable packers elements.
 Improve supplier performance
 Improve reliability and performance
Technical challenges addressed:
 Reduce elastomer extrusion
 Decrease the degree of elastomer degradation
 Improve the compatibility of elastomers with mud
 Prevent outer bladder separation
 Prevent plastic deformation of mechanical support

24. kalepa
tech
Sustainability
Consulting and Strategy
HIGH PRESSURE CHAMBER EVALUATION
DIVISION OF FORMATION EVALUATION
Electromechanical tools are used to characterize oil wells after drilling. The Modular
Reservoir Formation Tester (MDT) is a reservoir pressure and sampling tool that analyzes oil
well fluid properties such as pressure.
An effort to increase pressure ratings of sample chambers from 20ksi to 30ksi resulted
changing the material and design. The project produced technical recommendations and
alternative designs to determine the appropriate pressure rating of active and future
chambers.
Pressure test results, failure analysis and material studies revealed
Titanium Beta C sample chambers were suitable for
lower pressure service. Inconel 725HS was needed
for higher pressure service.
Standard testing, serializing, tracking procedures
were also implemented.
Stress(psi)
Strain
in/in
17-4 PH in 1075 Cond
Inconel 725
Ti-Beta-C (High
STA)
Qualitative Comparison of 4 Materials
MP35N
Ti-Beta-C (Low STA)

25. kalepa
tech
Sustainability
Consulting and Strategy
CRYOGENIC ELECTROMAGNETIC VALVES DESIGN
Thesis Abstract
A major limitation of Gifford-McMahon, G-M, cryocoolers is the requirement to conduction cool the
refrigeration load. Earlier attempts to use check valves to rectify oscillating pressure in an external
flow loop were unsuccessful. A G-M cryocooler was modified with Boreas style cold
electromagnetic valves to utilize oscillating pressure to drive unidirectional flow. Minimum leakage
and acceptable electrical dissipation even at 4.5 K was achieved. Preliminary analysis indicated
the G-M blow down process could be used to power the flow without degrading cooler capacity.
A paper under the same title was presented at the 11th Annual International Cryocooler Convention
in Keystone Colorado. The paper appeared in the Cryocoolers 11 publication in 2001.
Cryocooler
Valve
Head
Flexures
Coils
Moving Core
Back Iron
Valve Spring
Spring
Washers
Indium Seal
Valve
Housing