The KeyKrafter is a high precision key duplicating machine used by many home improvement stores. It has three phases of complexity: high precision key shape identification, bit measuring, and cutting. The document discusses various mechanical design projects including designing enclosures and packaging for aircraft inverters and batteries. It also covers designing frames and parts for Big Dog motorcycles including concept models, simulations, and prototypes. The first engineering job discussed was designing tanks for Brenner and VIM, making changes to improve quality, time savings, and comply with DOT regulations. Miscellaneous projects include a water tank trailer design and automated Pro/E and Solid Edge models.

1. The Hillman Group
The KeyKrafter is a high precision key duplicating
machine that is used by Home Depot, Wal-Mart,
Lowes, Ace, and Canada Tire.
The KeyKrafter has three phases of complexity:
1. High precision key shape identifier with over
500 keys in the database to compare to.
2. High precision bit measuring.
3. High precision, high repeatability, cutting.
• Technical lead design engineer responsible for all parts and performance metrics.
• Technical lead for production line for Kiosk, cutter module, and key ID scanner box.
• Technical lead for field return failure analysis, failure mode tracking, and corrective
actions with validation.

2. Mid-Continent Instruments 1/3
Designed the mechanical layout and packaging for the TI1200
aircraft inverter. It uses the same extrusion for the top and
bottom halves of the case. Each half has a different machined
configuration for component fastening.
Also, designed the mechanical layout and
packaging for the TI250 inverter with 2-
piece enclosure. It consists of an extrusion
(machined for fastening components), with
a single sheet metal cover with 90° flanges.

3. Mid-Continent Instruments 2/3
I designed a large portion
of this lithium-ion TB17
aircraft battery. This is the
first ever lithium-ion battery
to be DO-160 certified thru
the FAA.
One of several tools I designed and fabricated
in house for production line use. This one is
used during inspection of an altimeter
transmission.

4. Mid-Continent Instruments 3/3
Left: Designed the layout and packaging for the
MD93 aircraft clock with dual USB charger. The
machined components are also the solder tooling
Right: Re-designed this MD835
lithium-ion battery case to safely vent a
500ºF overcharge event.

5. I designed all 6 of BDM’s OEM frames that have 70+
parts per frame. This includes cast and machined
parts, bent/coped tubes, and sheet metal parts. I
performed all the FEA calculation. I created the
endurance test plan that included strain gage stress
verification at critical areas. I performed
manufacturing engineering duties for weld tooling
issues, weld schedule, weld quality, parts inspections,
and post-weld CMM verifications.
I designed the air filter cover, coil cover (on
other side), front engine mount, mirrors, and
other various cast and machined parts that were
often used in advertising.
Big Dog Motorcycles: My favorite job. 1/5

6. Big Dog Motorcycles: My favorite job. 2/5
Top: Conceptual springer front fork FEA, and accompanying calculations.
Below: Used ANSYS to simulate a
cracking fender bracket. The robust re-
designed bracket was created using
accelerometer measured vibration data.
Far Left: Swing arm and mounting
attachments meshed ready for simulation.
Left: Stressed front portion of frame using
half symmetry.

7. Big Dog Motorcycles: My favorite job. 3/5
Left: 2007 Bulldog
prototype frame concept
model. This was the
beginning of front curved
down tubes on our
models.
Right:Swing arm
front forged
concept model
overlay on
existing assembly.
Right: Initial
concept swing
arm model for
the 2010 Wolf.

8. Big Dog Motorcycles: My favorite job. 4/5
Below: Front engine mount designed as a bolt on polished aluminum part.
Above: Prototype K9 frame model.. Above: My 6th and final frame had a single curve down-tube,
X-Wedge engine, and closely spaced curved swing arm tubes

9. Right:
Some of
my work
on a t-
Shirt at
Wal-Mart.
Below: 2010 K9 with parts I designed years earlier - frame, swing arm, air filter cover, mirrors, coil cover,
front and upper engine mounts, and various polished covers. Me riding a 2006 R&D K9.
Big Dog Motorcycles: My favorite job. 5/5

10. VIM/BRENNER TANK: MY FIRST ENGINEERING JOB. 1/3
Right: Designed this VIM 11 compartment tank which
is able to haul nine 55gallon drums on the back end.
Left: Designed Brenner’s first insulated aluminum
asphalt tank with roll-over protection, surge protection,
and walkway. Many hours were spent reading DOT
regulations.
Right: A lot of work went into this VIM polished
aluminum 9,200 gallon tank that has many weld-on
options, and a special DOT stainless steal bumper.

11. Designed a complete new rear compartment system
on this 5 compartment 4,500 gallon tank.
Decreased manufacture time by 21 hours, and
greatly improved overall functionality.
VIM/Brenner Tank: My first engineering job. 1/1
This new design included an all new layout of
the metering fuel delivery components, wiring
scheme, and new pre-hung style framed doors.
Also, the new design achieved a system which
produced improved reliability and
performance.
VIM/BRENNER TANK: MY FIRST ENGINEERING JOB. 2/3

12. VIM/Brenner Tank: My first job. 2/2
I made numerous quality and time saving changes at
these companies that ranged from general design,
design for manufacturing, stress calculations,
programming fixes, drawing methodology, DOT
regulation interpretation, and legacy paperwork.
VIM/BRENNER TANK: MY FIRST ENGINEERING JOB. 3/3

13. Miscellaneous.
VIM Trailer water tank. I designed the
rolling chassis frame to hold this
fiberglass tank that was mounted by
Cessna. It was still in use 7 years later
when I started working for Cessna.
I created this automated Pro/E printing
cylinder model that is driven by
information from a Visual Basic app.
This is one of several automated models I
created at Bunting Magnetics to greatly
save engineering time on the individual
work orders.
I created this
Solid Edge
demo model to
display
versatility with
packaging's.