top of page

About Jeff

Hi, I’m Jeff Miller - I’m a pilot and engineer from the Detroit area. I grew up in a family of DIYers and classic car enthusiasts. My first exposure to aviation came through my father, who worked non-flying roles at  Republic, Northwest, and Delta airlines from the 1980s to early 2000s. Non-revving and hanging out at the airport was much easier in the pre-TSA era, so I spent much of my younger years riding on airliners, hanging out in terminals, and watching the planes land from the observation lot near 21R at DTW. 
 
During high school I became fascinated with science and technology, which led to me earning my Bachelor’s in Mechanical Engineering and Masters’ in Systems Engineering. After university I went to work in the auto industry and companies related to it, most recently working on controller design and integration on Tesla's autopilot hardware team.
 
Shortly after college, I revisited aviation - inspired by a co-worker and friend who was working on his Private Pilot Certificate, I started flying out of KPTK and was son a private pilot myself. 
 
For the next decade or so, I was content with bug-smashing my way around Midwest airports while designing automotive systems for a living. After a few more engineering gigs of increasing responsibility but decreasing work / life balance, I realized I had the urge to work outside a typical office. Realizing how much time I spent flying when not occupied with work, I decided to pursue aviation as a career.
 
That was back in 2022 - I’ve since earned my CFI/I, Instrument Rating, Commercial Pilot Certificate, Multi-Engine Rating, and Single-Engine Seaplane  ratings. I'm currently instructing with Crosswinds Aviation out of Willow Run Airport (YIP) near Detroit.
 
In my free time, I enjoy electrical and mechanical tinkering, RC planes, travel, spy novels & nonfiction, cooking, and volunteering for the Red Cross.
 
My extended resume is below, including details of each of my past positions. My one-page PDF resume is available from the link in the header above.

Blue Skies and Tailwinds,
Jeff Miller
27 December 2024

Extended Resumé

Pilot Certificates & Related Credentials

See PDF Resume for Current Hours

  • Commercial Pilot ASEL, AMEL, & ASES

  • Certified Flight Instructor & Instrument Instructor ASEL

  • Instrument Rating

  • High Performance Endorsement

  • Complex Airplane Endorsement

  • Tailwheel Endorsement

  • 1st Class Medical Certificate

  • Restricted Radiotelephone License

  • Valid US Passport

Aircraft Types

In order of experience level

  • Cessna 172 (N, M, L, R, S)

  • Piper PA-28 series (-140, -150, -160, & -180)

  • Diamond DA20

  • Cessna 172 RG

  • Cessna 152

  • American Champion Super Decathlon (BL8) 

  • Diamond DA40

  • Aviat Husky Floatplane (A1C)

  • Cessna 177

  • Cirrus SR22T

Employment History

  • Supporting Self with Savings and Investments
     

  • Currently pursuing pilot and instructor certificates and ratings 
     

  • Building hours in co-owned aircraft

​

  • Volunteering with Red Cross​​

April 2022 - Present

Self-Supported
Dearborn, MI

2017 - April 2022

Tesla Motors
Palo Alto, CA

Staff Mechanical Engineer - Electronic Systems

  • Led mechanical component and assembly design of Hardware 3, 3.5 and 4 liquid-cooled car computers for model S, X, 3, and Y vehicles.​
     

  • Led mechanical component and assembly design of Model S Plaid Gaming Car Computer, including AMD-based graphics card integration.
     

  • Co-developed and prototyped two proprietary mechanical design concepts to increase cooling efficiency of microprocessor systems and enable higher system loads without compromising safety margins. One concept is currently in the US patent process. 
     

  • Collaborated with overseas suppliers and Tesla supply chain to reduce costs of complex liquid cooled heat exchanger assemblies. 
     

  • Worked closely with thermal, integration, electrical design, manufacturing, materials, EMC, and several other teams to ensure all design requirements were met or exceeded.
     

  • Analyzed Material Review Board cases to enable use of otherwise obsolete material and prevent unsafe goods from reaching the assembly line.
     

  • Worked closely with sustaining engineering to troubleshoot technical issues with legacy iterations of car computer and infotainment systems.

Reason for leaving:
Change of career from engineering to aviation.

Tesla Motors
Palo Alto, CA

2016 - 2017

Senior Mechanical Engineer - Autopilot and Infotainment Systems

  • Designed parts and assemblies for air-cooled Media Control Unit and Hardware 2 and 2.5 car computers.
     

  • Troubleshot quality and technical issues at overseas vendors and contract manufacturers.
     

  • Developed thermal / fluid performance test procedures and hardware for liquid cooled computer heat exchangers.
     

  • Collaborated with Tesla supply chain team, contract manufacturers, and component suppliers to design a fully-automated car computer assembly line capable of building >5000 car computers per day.

Reason for leaving:
Promoted to Staff Mechanical Engineer.

2013 - 2016

Rofin-Sinar / Coherent
Plymouth, MI

Mechanical Engineer - Laser Manufacturing Systems​​

  • Performed sizing, beam-line, layout, motion, and safety studies for custom laser cutting, welding, and heat-treatment machines, based on customer requirements.
     

  • Designed tooling, fixtures, and robot end effectors for custom laser cutting, welding, and heat-treatment machinery.
     

  • Performed GD&T analysis for parts, assemblies, and processes. 
     

  • Assisted service team with troubleshooting of fielded machines.

Reason for leaving:
Offered Opportunity at Tesla Motors.

2012 - 2013

ZF Steering Systems
Northville, MI

Product Engineer II - Dual Pinon Electronic Power Steering Systems​

  • Served as North American subject-matter expert on Dual-Pinion EPS systems.
     

  • Aided in selection of materials for EPS housings, seals, and gears.
     

  • Performed GD&T studies to improve assembly process first-pass yield.

Reason for leaving:
Offered more attractive position at Rofin-Sinar.

2006 - 2012

Perceptron, Inc.
Plymouth, MI

Mechanical Design Engineer - Commercial Products Group

  • Designed miniature waterproof and chemical-resistant camera modules and housings for industrial borescopes.
     

  • Worked with electrical engineering teams to integrate image processing and camera systems into miniature enclosures and hand-held housings.
     

  • Designed mechanical components and assemblies for industrial borescopes.
     

  • Performed industrial design and user interface design for industrial borescopes.
     

  • Collaborated with executive and marketing teams to design, render, and prototype brand-customized industrial designs for use by executive team in developing new customers.
     

  • Collaborated with overseas vendors to design assembly processes, IQC and OQC processes, and identify cost-down opportunities.

Patents:

  • US D594,361 - Display housing for remote inspection device  · Issued Oct 9, 2007
     

  • US 7431619 - Detachable coupling for a remote inspection device · Issued Aug 24, 2007
     

  • US D594,362 - Display housing for video inspection device · Issued Aug 13, 2008
     

  • US D621,831 - Dongle for use with a video inspection device · Issued Sep 15, 2009

Reason for leaving:
Company instability combined with offer from ZF Steering Systems.

2005 - 2006

AGC Automotive
Americas
Ypsilanti, MI

R&D Mechanical Engineer

  • Planned and supervised material and component testing for Tier-1 supplier of automotive window and glass components.
     

  • Designed, built, tested, and validated pneumatic windshield impact test machine.
     

  • Assisted US R&D VP in quality audits at plants around the US and Canada.

Reason for leaving:
Opportunity to be directly involved in product design at Perceptron.

2000 - 2004

DuPont Automotive Coatings
Troy, MI

Lab Technician - New Products Group

  • Prepared prototype automotive primers, basecoats, and clearcoates from raw materials and intermediates.

  • Performed mechanical and chemical testing on prototype coatings.

  • Performed large-scale sample preparation for testing by big-3 automotive customers.

  • Analyzed data for six-sigma and other process improvement studies.

Reason for leaving:
Offered buy-out as part of company downsizing.

Volunteer Work

SE Michigan Disaster Action Team (DAT) Associate
Responded to house fires and other local disasters to connect victims with Red Cross disaster relief programs and perform victim intake.

American Red Cross
Detroit, MI Chapter

2023 - Present

Education

2013 - 2016

Lawrence
Technological
University
Southfield, MI

Master of Science in Mechatronic Systems Engineering

Earned degree while working full-time as a mechanical engineer.
Coursework:

  • Digital & analog control systems design

  • Sensor and actuator integration and control

  • Embedded system design and programming

  • Aerospace systems

  • Vehicle dynamics

Bachelor of Science in Mechanical Engineering

Earned degree while working full-time as a chemical engineeing technician.
Coursework:

  • Machine design

  • Thermodynamics

  • Strength of Materials

  • Materials Science

Oakland University
Rochester, MI

2001-2005

Areas of Expertise & Experience (Engineering)

Product Design

  • Specification / requirements development

  • PCBA integration into mechanical products

  • Optics integration into mechanical products

  • Functional / Rugged Enclosure design 

  • Microprocessor and electronics cooling

  • Rapid prototyping

  • Industrial Design ​

​

Manufacturing Engineering:

  • Assembly line design & planning

  • ​Tooling design 

  • Fixture design

  • Error-proofing

  • Statistical process control / Six Sigma

  • IQC and OQC processes

​

Materials Selection:

  • Aluminum Alloys

  • Steel Alloys

  • Engineering Plastics

  • Coatings and Adhesives

  • Metal plating & coatings

  • 3D printing materials

​

Machine Design & Mechatronics:

  • Machine sizing & layout

  • Mechanism design

  • Motion system selection

  • Robot end effector design

  • Sensor integration

  • GD&T

​

CAD Modeling and Drafting:

  • 3D Part and assembly modeling

  • 2D drawing creation, revision and checking

  • Product visualization & renderings

Manufacturing Processes:

  • Metal HP and LP casting

  • Stamping

  • Injection molding​

    • Multi shot​

    • Single shot

    • Insert molding

  • Compression Molding

  • 3-D printing (SLA, SLS, FDM)​​

  • CNC mill / lathe / machining center

  • Brazing & soldering​​

  • Laser processes

    • Cutting​

    • Welding

    • Marking

​

Design for:

  • Manufacturing processes (see above)

  • Assembly

  • Service

  • Electromagnetic Compatibility

  • Cost-effectiveness

  • Modularity

  • Inspection

​

General Engineering:

  • Engineering change processes

  • Material review board processes

  • Supply chain management

  • Supplier qualification

​

Product, System, & Component Testing:

  • Durability testing (HALT-HASS)

  • Test process development

  • Reliability testing

​

bottom of page