Intellex Acquires Expert by Big Village

We're thrilled to announce that Intellex has acquired Expert by Big Village, effective March 22, 2024. This strategic move enhances our capabilities and strengthens our commitment to delivering exceptional solutions to our customers.

Stay tuned for more updates on how this acquisition will benefit our clients and experts.

For inquiries or more information, please contact us at


Expert Details

Mechanical Engineering, Rocket Science, Research and Development: Manufacturing and Design

ID: 736859 Tennessee, USA

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Licensed mechanical engineer, rocket scientist, and former director of research and development with manufacturing and design experience as well as hands on experience with the retail and wholesale bicycle industry, nuclear industry, consumer products, license plate cameras, cooking appliances and automobile industries. CAD expert versed in Solidworks, CREO and NX. Structural engineering experience with cantilever retaining walls also.

• Solidworks (22 years, 25,000 hours) Sheetmetal, Parts, Assemblies, Molds, Drawings, Weldments, Simulation, Animation, Surfaces, Configuration Management, Model Based Definition, Photorealistic Rendering/Visualization, FEA
• Creo 4.0 (Pro E) Weldments, Framing Extension, Piping, Drawings, Rendering
•NX 11.0
•AutoCAD (16 years)
•COSMOS, NASTRAN Finite Element Analysis
•Microsoft Project, Project Libre
•PDMworks, Enovia, Solidworks PDM, Windchill, TeamCenter

Areas of Expertise and Special Skills:
Brake Dynamometers Rotary Eqpt. Dynamics Dynamic/Static Sealing IP67 Enclosures Lasers
Optics/Sources Structural Steel/Aluminum Thermal Analysis Fabrication Power Transmission
PFMEA/DFMEA GD&T/ANSI Y14.5 Conveyors Tool Design Procurement
Pressure Vessels Ceramics MIG/TIG Welding/Fixtures Test Equipment Vibration Mitigation
Project Management Robotics Electronics Packaging Machine Design Quality Assurance
Piping ROI Analysis Aerospace Ground Support Stress/Failure Analysis

Work History

Years Employer Title Department
Years: 2018 to 2019 Employer: SYNCRONESS-ULA Title: Structural/Piping Engineer/Rocket Scientist Department: Engineering
•Umbilical retract systems for spacecraft mobile launch platforms. (All designs in CREO)
•Structural steel, piping, gravity activated systems and cryogenic systems.
•Dynamics and Structural Analysis
•Design/Drawings/Drawing Checking/Revisions
•Aerospace Hardware Selection
Years Employer Title Department
Years: 2016 to Present Employer: Undisclosed Title: Engineering Consultant Department: Engineering
• Platforms, cranes, valves, conveyors, pressure vessels, ventilation, weld manipulators, electro-optics
• Brake Dynamometers: flywheel design, shafting, dynamic sealing, vibration mitigation
• Marina truss and deadman anchor interfaces
• Security X Ray Scanners. I used GD&T and Metrology (Design Verification) to resolve supplier issues, performing technical evaluations of critical attributes. (govt security industry)
• Traffic Cameras: Redesigned two new cameras and reduced part count by 30 to 50% in both designs using innovative sheet metal design and DFM techniques and materials selection (ITS industry)
Years Employer Title Department
Years: 2007 to 2015 Employer: 3M Title: Sr. Development Engineer Department: License Plate Recognition Systems
• Managed ECPs and the Change Management process
• Slate ALPR Camera and SupeRex 3 Processor: Developed and designed the world’s smallest, lightest and most innovative and accurate ALPR cameras, processors, opto-mechanical interfaces and brackets for police cruisers and fixed installations utilizing sheet metal, injection molding, metal die casting and machining methods, DFM, and thermo
- mechanical analysis. These products were 40% to 50% smaller than the older products. I sourced fabricated parts as well as developed test equipment, performed regulatory compliance testing, packaging and vibration and impact testing.
• Standard Mounting System: Designed a new rationalized camera mounting system that reduced 75% of cost from mounting systems and camera systems using Design For Assembly techniques.
• Slate Mobile Processor: Designed portable hardened processor capable of withstanding 45Gs with no damage. This also utilized low profile quick connectors that were waterproof.
Years Employer Title Department
Years: 2008 to 2015 Employer: CUTTING EDGE WHEELS/EDGE RECUMBENTS Title: Director of Research and Development Department: Electric Bicycles/Recumbent Bikes
Purchased bicycle division and redesigned and reintroduced the entire bike line with all long wheel base and short wheelbase bikes. A venture capital group purchased Edge and merged it with an existing e-bike firm. Was a member of the Board of Directors with executives such as the former President of Speedo International and the VP of Marketing at Jewelry Television Network.
• E2 Folding Recumbent Trike: developed a patented folding trike concept and managed introduction to the market and developed all tooling and processes for manufacturing. The trike remains the only folding trike that could fit in an airline check-able suitcase. It was nominated for best trike of the year by the top recumbent industry journal, Bentrideronline.
• Haiku: conceived of and designed the only low stepover hi-racer recumbent road bike. A Haiku took the gold in the endurance races at Sebring in the 60+ class. It was nominated for recumbent bike of the year.
• E-Lation: selected new e-bike frame designs that would appeal to targeted markets. Also conceived of and implemented rental of e-bikes in the most visited US National Park, gaining permission for the first use of e-bike rentals in the Park System.
Years Employer Title Department
Years: 1997 to 2006 Employer: CERAMASPEED Title: Sr. Design Engineer, Sr. Process Engineer Department: Smoothtop Range Electric Heaters
Developed processes and automation for the entire product line. Moved into Design Engineering and developed heater designs, packaging and tooling for all products. During this time, managed the NPI process, DFMEAs and the engineering department when the manager was not available. Used German skills to aid in translation when interfacing with our Austrian counterparts.
• Automation of complete factory: conceived of and justified and managed complete automation of the entire plant reducing labor costs by $2.5 million annually. Extensively used negotiation and presentation skills to sell the concepts to management. The systems were multi-axis electro-mechanical robotic units and used skills in motion controls to help develop the motion algorithms and control sequences necessary.
• Returnable Packaging and Customer Workcells: Saved $500,000 per year in labor and materials costs through value engineering in product design. Created $500,000 in new profit for customer through design of stove top harness assemblies. Saved $550,000 annually through development of new returnable packaging system by designing, working with suppliers and supervising and attending ISTA compliance testing.
Years Employer Title Department
Years: 1992 to 1997 Employer: ALLIEDSIGNAL SAFETY RESTRAINT SYSTEMS Title: Sr Manufacturing Engineer/Laser Cutting Department: Automobile Safety Restraint Systems
Managed and performed all justification for capital equipment procurement and implementation for a high volume automotive textile products plant. Managed maintenance and programming for four high power lasercutting and converting systems as well as all automated sewing systems. Used German skills to act as translator for the plant with our German equipment suppliers. Developed all PFMEAs for the plant and used 6 Sigma and SQC techniques.
• Laser Cutting: Reduced WIP and internal lead time by 90% in laser cutting area through use of 6 Sigma, line balancing, CAD nesting optimization, SPC, machine downtime root cause analysis, machine design and programming. This effort saved $750,000 annually.
• Sewing Optimization: Developed AutoCAD based graphic programming system for automated sewing machines that reduced programming time by 75% and enabled rapid changes creating huge flexibility in batch sizes and WIP reduction.
• QS 9000 work instruction implementation: Led this team to develop all work instructions for ISO9000 compliance.

Fields of Expertise

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