Terry Lee Portier, Engineer Page 1 of 3
NO ACTIVE CLEARANCE.
SUMMARY OF WORK EXPERIENCE
• 30+ years of aircraft bachelor degree engineering experience; EDUCATION: BSAE—-Northrop University, Inglewood, CA. FAA License: Airframe and Powerplant Mechanic. 1984.
• Design, Manufacturing, Ship-Side Support, Liaison /MRB, Ground & Flight Testing, Tooling, Maintenance and Modification (MRO), Quality Assurance.
• Extensive CATIA V6/V5/V4/ENOVIA, TeamCenter PLM/NX/Unigraphics, SolidWorks, Creo/ProE, IVT/PDM/SAP/MES/PIOS/IMS experience. CATIA V5/V6 Tubing workbenches.
• Primary and secondary structures (composites (lay-ups, fiber placement. filament wound) metals, payloads, electrical, avionics, landing gear, ECS, HVAC, fuel, hydraulics, flight controls, FAA Certification (FAR 23/25/JAR/EASA), STC’s.
• Experience in commercial, military, wide-body, business jets, and helicopters.
• Nacelle & Pylon, Flight Deck, Cabin, Empennage, Wings, Control Surfaces, Interiors (galley’s, lavs, stow bins, seats.)
Design: CATIA (50,000+ hrs): V6/V5/V4 CATIA/ Enovia, PTC Creo/ProE/WindChill, Siemens NX/Unigraphics, SolidWorks, AUTOCAD, CADAM: CADD, Mentor Graphics, NCAD. FEM: Nastran/Patran (level 1), CFD: FLOEFD/ FLOMASTER/FLUENT/FLOSIM. Composites: Fibersim, CPE/CPM: MS Office, PDM, SAP, DOORS, VISIO, Labview, Chameleon.
EDUCATION: BSAE, 1984—Northrop University, Inglewood, CA FAA License: Airframe and Powerplant Mechanic.
Summary of Structural, Mechanical, and Electrical/Avionics: Diversified in the design, development, analysis, testing, certification, manufacturing, and maintenance. In addition, proficient at CAD_CAM, documentation writing.
Test and Certification Engineering Director (Spacecraft)
Mechanical/Structural/Avionics/Electrical/Hybrid Propulsion 8/1 – current
The Space Ship Company, Mojave, CA
Virgin Galactic, Spaceship 2/Whitenight 2: Direct and manage 14 CFR Part 25 testing verification and validation test for new design/modification efforts. Develop Ground/Flight component/system level test instrumentation, data acquisition, and analysis. Develop requirements for certification basis and MOC. Design and determine test benches, procedures, integration. Perform life cycle analysis, technical risk assessment, 14 CFR 400-460 existing/future launch site analysis, lean production. Manage various test DO-160, MIL-STD-461/810G, test stands; fluid susceptibility/resistance, temperature, humidity, salt-fog, op-shock and vibration including table design/modal/rocket analysis, icing-freeze-thaw, sand & dust, fungi, waterproofing, salt spray, explosive atmosphere, pressure & leakage, altitude, decompression/ over pressure, bagginess & ballooning, avionics & electrical; (EMI/EMC), power input, voltage spike, magnetic effect, lightening, electro-static discharge, audio frequency, electrostatic discharge, for component and system level verification and validations. Design, conduct, and execute calibrated and non-calibrated instrumented test, command center software functionality, simulated aircraft interfaces, pass-fail, data acquisition, logs, and artifacts. Structural (metallic/composites), mechanical (fluids, pneumatics(RCS), flight controls, etc. Conduct PTR/TRR/TCR with Program Managers and Chief Engineering Office. Write QTP/QTR’s. Perform system architecture FHA, SSA, FRACA, FMEA, RCCA. CATIA V5/Solidworks/FEMAP/NASTRAN, Labview,DOORS, Smarteam.
Propulsion Test and Certification Engineer (Engine & Nacelle) 8/17 – 5/18
GulfStream Aerospace, Savannah, GA
Cognizant (SME) responsible for 14 CFR Part 25/33_EASA CS-25/AMC, Powerplant; Fire Protection, Mechanical, Systems (Engine, EBU, Nacelle, TRU), Equipment, Structures, Electrical/Avionics, Installations. Manage engine and nacelle domestic and foreign suppliers for regulatory conformity and compliance, TRRs/TCRs, to meet certification and program milestones. Develop and manage program risk reduction protocols; SOF, ground/flight, test, certification paths, verification/validation, and compliance plans (QTPs/ATPs/QTRs/drawing(test articles). Develop new DMU engineering (MBD’s/design data packages (OPK), PLM, as certification basis for Amended Type Certificate. Establish MOC (Means/Methods of Compliance). High level of coordination with company Unit Members, propulsion ODA/ EAR/ IAR for 8100-9, 8130-3/-9, and other regulatory approvals. Review and establish compliance testing paths for fireproof/fire resistant component’s/singularities; detection, containment, isolation, distinguishing, flammable fluids, drainage, overheat, smoke, EVAC, flight deck indications (CAS) per AC-20-135/ISO2685/FAA Fire Test Handbook. Develop RTCA DO-160, etc, structural (metallic/composites), mechanical (fluids, flight controls, pneumatics, etc), electrical/avionics, test procedures, test set-ups, pass-fail criteria for ODA on-site and/or virtual reality witnessing. Manage various test DO-160 test stands; fluid susceptibility/resistance, temperature, humidity, salt-fog, op-shock and vibration, icing-freeze-thaw, sand & dust, fungi, waterproofing, salt spray, explosive atmosphere, pressure & leakage, bagginess & ballooning, avionics & electrical; (EMI/EMC/Power), MIL-STD-461, power input, voltage spike, frequency, electrostatic discharge, for component and system level verification and validations. Design, conduct, and execute calibrated and non-calibrated instrumented test, command center software functionality, simulated aircraft interfaces, data acquisition, logs, and artifacts. Perform system architecture FHA, FRACA, FMEA, RCCA. CATIA V5, DOORS, Smarteam.
Test and Certification Project Lead Engineer (contract)
Mechanical/Structural/Avionics/Electrical 10/16 – 7/17
Cobham Mission System, Davenport, IA
Write and execute Quality Test Plans (QTPs) based on customer and FAA certification requirements. Verify design compliances per FAA ground/flight test certification and/or Supplemental Type Certificate (STC) per AC-23/25/ 14 CFR 23/25, AFPD 62-6, MIL-HDBK-516, ARP 4745 MIL-STD-810, RTCA-DO160/178/254. Produce Experimental Flight Release Basis (EFRB), Artifacts Assessments, Gap Analysis. Supervise, create, and coordinate Request for Conformities (RFCs), work orders, test deviations. Design, conduct, and execute calibrated instrumented test, command center software functionality, simulated aircraft interfaces, data acquisition and logs, for structures, mechanical, sub-systems; hydraulic, fuel, ECS, fluid susceptibility, temperature, humidity, salt-fog, shock and vibration, icing-freeze-thaw, sand & dust, explosive atmosphere, avionics & electrical (EMI/EMC/Power) MIL-STD-461, for component and system level requirements validations and other applicable testing. Participate in communications and reporting to internal and external customers. Direct coordination with Integrated Product Team IPT) testing efforts with test pilots, technicians, MRO’s, client delegated authorities (ODA-QA/UM), FAA. Liaison with Design Engineers and production personnel on various test platforms, mission critical components and configurations. Transform prototype concepts to production ready to support LRIP/PRR. Field service support & development of maintenance manuals (SRM/AMM), parts catalogs (IPC), wire diagrams (WWC). Conduct Fault Tree Analysis FTA (FRACAS/5Y/DFMEA), disposition Non-Conformance Reports (NCRs), facilitate repair procedures. Develop test fixture, tool and jig, repair and modification engineering drawings. Analyze test data for conformity, Safety of Flight (SOF), Risk Assessments, and for back calibrating computer modeling and developing empirical data. Author final Quality Test Reports (QTR) for use in aircraft certification. Aircraft and Rotocraft.
Software: CREO PRO-E/CATIA, WINDCHILL, DOORS, VISIO. Write graphical code syntax, Labview, Chameleon. Conduct GD&T (tolerance stack analysis), FEM, VSA.
Structures Engineer (contract) 6/16 – 9/16
UTC, Chula Vista, CA
Integrated design and definition of primary and secondary nacelle structures defined by CATIA/Enovia MBD (Model Based Definitions), Relationship Designs, in an IPT (Integrated Product Team) release environment. Develop robust designs/redesigns, support testing, integrated 3D model based; manufacturing plans, tooling, inspection criteria and quality processes life cycle managed by Enovia. Design carbon/ fiberglass and metallic sandwich construction: laminates, beam analysis, core, bond lines using Fibersim software. Developed bolted assemblies incorporating DA hole assemble methods for tooling cost reductions and lean manufacturing. Respond to field anomalies, redesign. Manage supplier development test and production activities. Coordinate with the suppliers to optimize the design and achieve program goals. Preliminary stress analysis. CATIA V5/Enovia/PDM. See additional UTC Experience below.
Mechanical Systems Engineer (contract)VTOL 1/16 – 5/16
Boeing, Philadelphia, PA
Design, redesign, development, test and certification of various military rotorcraft configurations. Relationship and integration design of Hydraulics, ECS, Fuel, Controls, Mechanical, and Propulsion systems to include heat transfer and pneumatic flow. Analyze composite and metallic structural load impacts using hand calculations and/or software. Design pumps, reservoirs, accumulators, sumps, valves, actuators, regulators, heat exchangers, tubing, ducks, hoses, manifolds, plenums connections, electric boxes and grounding, weld assemblies. Design_Build to cost and robust manufacturing technologies; MBD (Model Based Definitions) 3D and 2D drawing definitions utilizing CATIA V5/ Teamcenter/ Siemens NX/Unigraphics. See additional Boeing experience below.
Mechanical Systems, Propulsion Engineer (contract) 9/15-12/15
Textron Aviation, Cessna, 3 Cessna Boulevard, Wichita, KS 67215
New design, vehicle integration, ground testing, and certification of mechanical installations to include APU. Develop structural provisions for fuel, ECS ducks, gears, manifolds, plenums, and fire protection systems including metallic and composites for prototype testing and production. Analyze heat transfer and thermal models, cooling, and insulation requirements. Develop system architecture and fluid flows to meet certification and customer requirements. Design fuel systems and architecture drawings; interface pumps, reservoirs, accumulators, sumps, valves, actuators, regulators, heat exchangers, mechanical and electrical connections, electric boxes and grounding provisions. Perform design to cost and maintenance trade and field studies to meet customer requirements. Air Vehicle integration and relationship design. CATIA V6/Enoivia/PDM. See additional Textron/Beechcraft/Cessna experience below.
Mechanical Systems Engineer (contract)
BAE/Scaled Composites, 16921 Airport Blvd. Mojave, CA 93501 6/15 – 11/15
Preliminary clean sheet design and development of the Stratolauncher aerial rocket launcher. Develop mechanical systems architecture, drawings, and documentation to satisfy customer, FAA certification and flight test support per AC-25, safety requirements and supply chain. Analyze fuel, ECS, hydraulic fluid flows, pressures, temperatures, capacities, kinematics, composite and metallic structural load impacts using hand calculations and/or software. Design fuel tanks and architecture; pumps, gears, reservoirs, accumulators, sumps, valves, actuators, regulators, heat exchangers, tubing, ECS ducks, manifolds, plenums connections, electric boxes and grounding, weld assemblies. Integrate sub system components to air vehicle, APU, cockpit indications. Develop installation procedures and provide shop support. Develop test plans for compliance with FAA certification requirements. Perform make-buy trade studies. Integration and relationship design of the Fuselage, Wing, Empennage, Landing Gear, Pylon, APU and Engine. CATIA V5/PDM/AUTOCAD.
Test and Certification Project Lead Engineer (contract)
Eaton Aerospace, 300 S. West Street, Jackson, MI 49203 12/13 – 8/14
Team Lead design, fault tree analysis, cause and corrective action, troubleshooting, test, repair, of hydraulic, ECS, and fuel system components, mechanical systems, materials technologies, architecture, certification, and integrations. Support customer Military/FAA Flight Test Certification for Type Certificate and/or STC verifications/compliances per MIL-STD-810, RTCA-DO160/178/254, AFPD 62-6, MIL-HDBK-516, ARP 4745, qualification, and/or certification issues. Liaison with Design and Production on various test configurations, preparations, and maintenance. Facilitate lab Quality Test Plans and set-up per customer requirements (quality and quantity, production, field, and acceptance) to support flight test, designs, and re-designs. Lead aircraft integrations of landing gear, engine, brakes, clutches, valves, motors, pumps, swivels, power transfer units, integrated power packs, generators, flow control modules, reservoirs, accumulators, tubing-hoses, fitting’s, fluid control, couplings, connectors, clamps per MIL-STD-810, RTCA-DO160. High level of internal and external customer interface. Preliminary stress analysis calculations, CFD and FEA modeling, fluid flow, pressure, temperature, and velocity gradients, capacities, sizing, and comparisons for lab testing and back calibration of models to optimize design. Analyze data, write Final Quality Test Report. CATIA V5 /Enovia. Write graphical code syntax.
ECS Engineer (ECS) (contract) 1/13 – 8/13 Cessna Aircraft, 3 Cessna Boulevard, Wichita, KS 67215
New ECS certification of systems and secondary structures, tooling, design-to-build planning of anti-ice and fire-protection, defrost, cabin, cockpit interior, fuselage, engine, wing. High level of composites and metal. Rapid Prototype design using Stereo lithography (SLA/SLS) complex ducting, Fused Deposition Modeling (FDM), injection molding, advanced composite tooling and assembly methods to support flight test. Design lean production rates, producibility, cost and schedule. Fibersim/CPD/CPM design of graphite and fiberglass ducts, tubing, and structural components. Vendor coordination of Resin Transfer molding (RTM), Vacuum RTM, Fuse Temp Molding. Supply air, heat transfer, temp control, pressurization systems, oxygen systems, emergency systems, ice protection, defog, service air, pitot static, bleed air, vapor cycle, clamping, shrouds, sleeves, mil specs. Interior design for pilot ergonomics. MRB disposition of production discrepancies. Internal and external customer coordination. Preliminary hand calculations, CFD and FEA analysis, fluid flow; pressure, temperature, and velocity gradients, capacities and sizing, and comparisons for lab testing and back calibration of models to optimize design. .
Structures Propulsion Engineer (contract) 5/11-12/12
UTC AeroSystems, Goodrich AeroStructures, 850 Lagoon Dr. Chula Vista, CA. 91910
Multi-task Engine Nacelle and Pylon design-to-build of primary/secondary structure, mechanical equipment and systems for cost reductions. Fuel, ECS ducting, electrical, avionics, hydraulics, engine and APU controls, ground equipment, for robust designs/redesigns, testing, manufacturing plans, tooling, and quality processes including internal and external supply chains to facilitate lean production rates. Consolidate structural and system requirements for robust assembly tool and manufacturing process, to include structural Fibersim composites, metals (aluminum, steel), plastics; DA hole concepts, tolerance analysis, GD&T, FT&A techniques. Implement customer, certification and FAA requirements. Design-redesign FAJ/AJ and detail tooling sheet metal stretch and form dies, extrusion dies. MRB disposition of production discrepancies. Preliminary hand calculations, CFD and FEA analysis, fluid flow; pressure, temperature, and velocity gradients, capacities and sizing, and comparisons for lab testing and back calibration of models to optimize design. .
Structures and Fuel (contract)
Boeing, Mukilteo, WA 9/10-5/11
Multi-task preliminary structure/system payloads, interior design, and modification to support KC-46 USAF Tanker flight test. Develop, integrate, and document structural composite, metal, interior payload system requirements, tooling and manufacturing planning, to establish the design. Produce layouts of major frames, interior monuments, and Aerial Refueling system architecture (tanks, and systems components). Develop fuel systems architecture to meet customer requirements. Design installations, assemblies, details, modification, test and conformity plans, assemble and detail fab tooling. Manage supplier development, test and production activities. Coordinate with the supplier to optimize the design and achieve program goals. DA hole concepts, tolerance analysis, GD&T, FT&A techniques. Implement 14 CFR 25 certification amendments, STC requirements, Flight Test Protocols. Preliminary hand calculations, CFD and FEA analysis, fluid flow; pressure, temperature, and velocity gradients, capacities and sizing, and comparisons for lab testing and back calibration of models to optimize design.
Manufacturing Engineer, Structures and Systems (contract)
Boeing & Vought, 3455 Airframe Dr. Charleston, SC 29418 6/09-8/10
Develop, integrate, tool, plan, and interrogate 787 composite CFRP barrel sections, payloads, interiors monuments (stow bins, lav’s, galley, seat tracks) design-builds: flight controls, hydraulics, ECS ducting, fuel, electrical, avionics, hvac, water, using lean technologies. Develop carbon fiber-reinforced epoxy pregs for 787’s primary/secondary structure in unidirectional tape for fiber placement, woven fabric, metallic forms, manufacturing technology for enhanced material lay-down rates. Develop composite structure closely with both internal and external Design and Material-Process Engineers to optimize autoclave cure rates, placement and tooling methodologies, void and delamination control, reduced corrosion and inspection cycles, geometry and configuration control. Develop plans for advanced auto-cutting, drilling, and fastening processes. Ship side support design process improvement. Assist in providing manufacturing information for inclusion in project plans and help document shop best practices.
Structures Engineer (contract)
Boeing & Spirit Aero Systems, 3801 S Oliver Wichita, KS. 67278 1/06 to 4/09
Preliminary design of 787, 747-8(P/F), 777F, 737. payloads, tool and manufacturing of advanced fiber placement systems, preforms, lay-ups, of composite and metallic primary and secondary structures, system components (fuel, hydraulics, flight controls), Interiors (galley’s, lav’s, seats, cargo), in accordance with Boeing structural design guides and standards, and FAA certification requirements. . Preliminary hand calculations, CFD and FEA analysis, fluid flow; pressure, temperature, and velocity gradients, capacities and sizing, and comparisons for lab testing and back calibration of models to optimize design.
Hawker Beechcraft/(Raytheon) Aircraft, Wichita KS. 12/02-1/06
Structures, Liaison, Systems ,Manufacturing and Tooling Engineer responsible for wings, control surfaces, interiors, mechanical, electrical, avionics, fuel, oxygen, ECS, hydraulics, HVAC and general system design and repairs. Part 23 Military Trainer Type Certification, ground and flight testing.
Liaison – Modification Engineer (MRO) (contract) – Structures/Electrical
Boeing Company, Wichita, KS. 1/97 to 10/02
Maintenance and Modification Test & Design Engineer responsible for the re-design of the KC-135. Design MRB repairs, modification kits/ tooling and field service assembly processes for structures, fuel, and electrical systems for the Air-Force and Tinker AFB. MRB disposition of non-conforming parts. Root Cause and Corrective Action investigations. Interpret and conform maintenance manuals (SRM/AMM), parts catalogs (IPC), wire diagrams (WWC).
Engineer Lead – IPT/DBT/Project Manager – Structures, Mechanical, Electrical
Hawker (Raytheon) Aircraft, Wichita, KS. 1/96 to 12/96
Section Manager responsible for the new design, development, and manufacture of the empennage of a new world-class business jet. Design, Tooling, Manufacturing, Cost and Schedule. Part 23/25 Type Certification, ground and flight testing.
Structures Engineer – VTOL
Boeing Company; Wichita, KS, and Philadelphia, PA. 7/91 to 12/95
Team member responsible for the design and development of several new and existing aircraft and helicopter programs, 737, 747, 767, V22, Chinook Rotocraft. Experienced in several areas of the aircraft. Responsibilities include structures, electrical, mechanical systems.
Structures Installation Design Engineer1/91 to 6/91
Northrop Corporation, Palmdale, CA
Installation design of major aircraft matting sections, composite structures and systems.
McDonnel Douglass Corporation, St. Louis, MO. 1/89 to 12/90
Responsible for the design and development of a new military aircraft. A-12(Secret access required). Secret Clearance.
Liaison/Quality Engineer 1/84-1/89
Northrop Corporation, Pico Rivera, CA.
MRB certified repairs, troubleshooting, Quality Engineering and Inspection, of composite structures and systems. Secret.