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Product Design & Consulting

In addition to being a commercial pilot, Jeff has has nearly 20 years' experience as a mechanical product engineer. He has brought parts, assemblies, and whole products from the drawing board to mass production for some of the world's most recognized companies, including Tesla, Coherent, and ZF.  Jeff is available for consultation and design work worldwide.

Areas of Expertise

Functional Enclosures

  • Water & dustproof enclosures

  • Liquid cooled electronics

  • Ruggedized products

  • Design for IP & IK ratings

  • Design for usability

  • Integration of electronics,
    sensors, & displays

  • Industrial design &  styling

  • Physical UI design

Fixtures & Workholding

  • Assembly & inspection fixtures

  • Go/No-Go gages

  • Robot end effectors

  • Automated fixtures

Prototyping

  • Proof-of-concept prototypes

  • Product / assembly prototypes

Design for Electromagnetic Compatibility

  • Emission reduction

  • Susceptibility reduction

2D & 3D CAD

  • CAD model creation

  • 2D drawing creation

  • Product Visualization

Mechatronics

  • Machine design

  • Mechanism Design

  • Robot integration

  • Sensor integration

Vehicle Integration

  • Design for vehicle integration requirements

  • Mechanical and electro-mechanical integration studies

  • Design for maintenance 

  • System interaction studies

Product Documentation 

  • Product manual content

  • IP filing content

  • Training material development​

DFM / DFA / DF(X)

  • Manufacturing process
    selection & design

  • Design for virtually any manufacturing process

  • Design for automated & manual assembly

  • Design for service  and maintenance

  • Design for security

Tolerance Analysis / GD&T

  • Tolerance analysis

  • GD&T analysis & implementation

  • Statistical tolerance analysis

Product Development

  • Requirements analysis

  • Feature development

  • Product line development

Materials Selection

  • Metal alloys

  • Polymers / plastics

  • Coatings & Adhesives

  • Plating & surface treatment

Past Customers & Employers

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Patents

Display housing for remote inspection device​
US D594,361 · Issued Oct 9, 2007
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Detachable Coupling for a Remote Inspection Device

US 7431619 · Issued Aug 24, 2007
 

Display housing for video inspection device

US D594,362 · Issued Aug 13, 2008

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Dongle for use with a video inspection device

US D621,831 · Issued Sep 15, 2009

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