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ASME Channel Islands Professional Chapter Engineer of the Year
Donald “Geoff” Carter
January 20, 2016
Dennis Horwitz, Chair
Engineer of the Year
Donald Geoff Carter
President and Founder,
Link Engineering & Design
Professional Engineer (P.E.)
ASME Member, Former Section Chair
Innovative, practicing lead design/mechanical engineer since 1996
B.S. and M.S in Mechanical Engineering, Cal State University Fresno
• 4 patents issued and 2 pending
• Specialist in space deployable mechanisms and structures
• Numerous space achievement awards
• Telescopic booms, Coil-able booms, Articulated Booms, Solar Array Wings
• Precision Mechanisms and Structural Analysis
• Built his own home in Santa Paula over 8 years
Donald Geoff Carter
Education and Professional Development
Donald Geoff Carter
Career Chronology
Donald Geoff Carter
Career Highlights
Flexible leadership skills wearing many diverse hats for each phase of the program:
concept, design, analysis, procurement, build, testing, and management.
• Lead Design Engineer bringing several high profile space flight projects such as,
STP-SIV, NuStar Adjustment Mechanism, NPOESS Solar Array and the JMAPS
Solar Array from concept to deliverable.
• Notable experience in the space structures industry designing Telescopic Booms,
Coilable Booms, Articulated Booms, Solar Array Wings, military APU packaging,
precision mechanisms and structural analysis.
• Bringing high volume products to the marketplace for large OEM’s and awarded
three US Patents for superior product innovation.
• Developed the mechanical structure and kinematic mechanisms for Star Wars Darth
Vader robotic toy arm, which received the Educational Toy of the Year award at the
International Toy and Hobby Show.
• Received service awards such as Perfect Attendance three simultaneous quarters,
and an A3 Performance award coupled with stipend for completing project ahead of
schedule and under budget.
• Successful projects include a very diverse list from consumer products to space
flight hardware.
Donald Geoff Carter
Engineering Expertise
• 80-100 design projects completed
• Project Manager/Lead Design Engineer
• Managing manufacturing and assembly lines for product development/launch
• Working in multi-functional team environment
• Conducting preliminary and critical design reviews
• Liaise with overseas manufacturers and customers
• Feasibility studies / cost savings analysis
• GD&T, ANSI Y14.5, DOD-STD-100 standards.
• Precision mechanism design/kinematic analysis
• Design for assembly/manufacturing
• Failure analysis
• Electric motors and pumps
• OEM high volume injection molding, die casting and metal stamping parts/products
• CNC and sheet metal design
• Rapid prototyping - with plastics and metals
• Instructed Pro/E training classes for other engineers
• Pro Engineer Expert - (18000+ hours experience)
• Pro Mechanica Structure - stress/thermal analysis & simulation
• Microsoft Excel, Access, Word, Power Point, Project
• Solid Works, AutoCAD and MathCAD
• Ansys Workbench 16
Donald Geoff Carter
Volunteer Work
Link Engineering And Design
“You are bound only by the grips of your
imagination…”Donald G. Carter, PE
Link Engineering And Design
About Link Engineering And Design
Product Development and Engineering Firm
Founded in 2014
15+ years in consulting Machinery
Mechanisms
Aerospace
Automotive
Agriculture
Food industry
“Dedicated to bringing your projects to completion”
Link Services
• Mechanical Engineering
• Electrical Engineering
• Stress / Thermal Analysis
• Systems Engineering
• Industrial Design
• Drafting / Modeling
Clients
Consumer Products Aerospace
Network / Computer Toys
Software
CAD
ProE - Mechanica
Solidworks - Cosmos
MS Office Suite
Word
Excel
PowerPoint
Project
MathCAD
Project Portfolio
Consumer Products / Toys
Toys: Darth Vader Arm
Robotic Arm with gripping action, articulating wrist and elbow.
Complete Design / Build
Mechanism Design
Structural Analysis
Customer: Uncle Milton Toys
Educational Toy of
the Year Award!
Click on the picture
Toys: Interceptor AeroX Launcher
Design / Build
Mechanism Design
Two independent gear trains.
Clutch Design
Launch Mechanism
Structure Design / Analysis
Customer: Estes Rockets
Remote control tank with integrated
plane launcher.
Enclosure: Power Strip
Design / Drafting / Build
Analysis
Rapid prototyping
Electronic Packaging
Custom electronic switches
New high voltage contacts
Customer: Maverick Power
Systems Inc.
Description: This power strip
provides both AC and switchable DC
power with over load protection.
Sports: Face Mask - Baseball
Concept to product.
Industrial Design
Analysis
Mechanism Design
Ergonomics
Customer: Grounder Guard
Description: A lightweight removable
safety mask for youth baseball. Mask
pivots out of way when not in use. It
can withstand a 70mph baseball
direct hit.
Network Encrypting Router and Key
Low part count – combined multiple components
Passive cooling Industrial design Ruggedized Key Fob
x.o.ware (Injection Molded Enclosures)
Samsung Tablet Cradle
Adapt existing tablet for medical use Multifunctional assembly
In and out of operating room
Ergonomic docking features for ease of use Maximize screen area Industrial design
Arthrex California Technology(Injection Molding)
Project Portfolio
Aerospace Pojects
Deployable Space Systems
Solar Arrays for spacecraft
Mechanism design for
outer space
Materials selection
Aluminum
Titanuim
Steels
Carbon Fiber
Stress analysis
Thermal Analysis
Testing
Design for severe
environments
Link Engineering And Design
Aerospace: NuSTAR
Complete Design
Piece Part Stress Analysis
Mechanical Characterization Testing
ATK Space Systems / Jet Propulsion Lab
Mast Adjustment Mechanism for the Nuclear Spectroscopic Telescope Array. Precision adjustment to micro-radians.
Aerospace: Telescoping Boom
Complete Design
Composite / Aluminum / SS
Deployable / Retractable
Accurate & Repeatable
High Stiffness
5’ – Stowed
20.5’ – Deployed
Customer: Able Engineering
Description: Structural telescoping
boom with high stiffness / torque /
push force. Completed as a R&D
project.
Aerospace: NPOESS
Lead Mechanical Engineer
Manage Mechanical Team
Deployment System
Synchronization System
Piece Part Stress Analysis
Design Trade Studies
Customer: ATK Space Systems
Description: National Polar Orbiting
Satellite System. Solar array wing
system. Deploys 9 accordion style
panels 4.5’ x 13.5’ x
Project Portfolio
Machinery
Machine: Enclosed Conveyor
Concept / Design / Drafting
Analysis
Mechanism Design
Material: SS 316L
13’ wide x 7’ tall x 180’ long
Weight = 80,000 lb
Manage demolition and installation
Customer: Leprino Foods
Description: Food processing
conveyor designed in Pro Engineer /
Pro Mechanica. Successfully
installed in Lemoore, Ca. 2000.
Machine: Rotary Cutter
Concept / Design / Drafting
Analysis
Mechanism Design
Material: SS 316L
Conducted Feasibility study
Used 4 HP rotary action to
replace 50 HP hydraulic
slicer.
Customer: Leprino Foods
Description: Food processing
product slicer designed in Pro
Engineer / Pro Mechanica.
Successfully installed in Lemoore,
Ca. 2000.
Eco Motors
OPOC Engine
Opposed Piston Opposed
Cylinder
2 stroke diesel
4x power density compared
to contemporary 4 stroke
engine
Electrically Controlled
Turbocharger (ECT)
EcoMotors – OPOC Rotating Components
OPOC components
OPOC Engine Optimization
Engine Operating
Points on
Compressor Map
5kW Generator using 80cc opoc™
Engine
Conceptual Sketches
Design / Drafting / Build
High density electronic Packaging
Thermal management
Twin throttle mechanism design
Intake manifold design
Fuel tank design
Quick release system
Customer: Advanced Propulsion Technologies Inc.
Standalone 5KW auxiliary power
supply for military applications. Quick
release pins to remove base power
unit for vehicle integration.
Packaging: Military Power Supply
EcoMotors APU – prototype build
Refined the design, added support packaging
and tailored to military needs
EcoMotors – ECT development
Electrically Controlled
Turbocharger
2.5 kW Electric Motor
5kW in Development
Reduce / eliminate turbo lag
Waste Heat Recovery
Project Portfolio
Analysis
Backed up with Traditional Analyses
Finite Element Analysis
Optimization of components
Stress
Strain
Modal analysis
Airflow (CFD)
Static Stress Analysis
Von Mises
Over stressed?
Under stressed?
Stiffness or strength driven?
Mechanism: Hitch safety device
Design / Drafting
FEA Analysis
Mechanism design
Customer: Entreprenuer
Description: A line of trailer hitch
products including de-coupling
system, forged hitch with quick
change hitch balls and dead-band
removal system.
Thermal Analysis
Reverse Engineering(2013 Mustang Intake)
Captured all ports locations / Geometry
Captured all geometry for clearance indentations
Vehicle
clearance
features
MAF Sensor
location
Breather
Ports
Pressure Flow Preliminary Analysis
Pressure differential of 1.6 psi overall
Flowing 1000 cfm maximum
Pressure Flow Animation
Qualities of an engineer – my opinion
Inquisitive – How did they do that? How does it work?
Imaginative – Dream big
Not afraid to try something new
Learn by doing – books are great, but the greatest
knowledge is hands on experience
Learn by failure - no one likes to fail, but the greatest
knowledge is gained from not succeeding the first
time
Persevere
Works well with others?
Link Engineering And Design