David Wilusz

- Design equipment for emergency and work vehicles. Products include center consoles, dash monitor mounts, rear storage, and electronic equipment brackets. Products are primarily sheet metal, with some plastic injection molded parts.
- Use a 3D scanner for vehicle fitments. Often requires disassembly of trim in vehicles. Also work directly with vehicle manufacturer’s CAD files.
- Use SolidWorks to provide preliminary designs, drawings, marketing material, install instructions, and final renderings.
- Work directly with manufacturing for all steps of product launch. On-site capabilities include laser-punch presses, brakes, welding, powder coating, injection molding, and assembly.
- Travel to Michigan for vehicle installs in pre-production or hard to find new vehicles.

- Establish product requirements with input from product managers, buyers, and industrial engineers for the purposes of aftermarket sales.
- Design and test aftermarket automotive products, utilizing both internal and external labs.
- Develop test plans for a range of parts in multiple part categories.
- Operate a 3D measurement arm (FARO Arm), optical comparator, hardness tester, and tensile tester.
- Design CAD models of wheel hubs, harmonic balancers, cable assemblies, and pulleys using SolidWorks.
- Utilize Geometrical Dimensioning and Tolerancing (GD&T) to complete drawings for manufacture.
- Coordinate with manufacturing vendors for schedule-driven delivery of parts.
- Rigorously test products to meet automotive standards.
- Assist and correct warranty issues.
- Specialize in cast machined and stamped parts such as wheel hubs, oil pans, harmonic balancers, and pulleys.

- Manage development of commercial-grade lawn care equipment through entire new product launch: timeline construction, budget and design constraints, concept generation, initial design and quoting, final design for manufacture, testing, packaging construction, pilot implementation, and product launch.
- Directly communicate with local and oversea suppliers for tooling, manufacture, assembly, packaging, and testing of parts.
- Use SolidWorks to provide product renderings for sales and marketing.
- Travel to and work with local plants for manufacture, final assembly, and testing of parts.
- Determine and implement engineering changes for improvement and cost reduction of current product line.

- Heavily use SolidWorks and several 3D printers to transform concepts into 3D models for manufacture.
- Co-inventor for three patent pending cleaning supplies.
- Develop products through entire new product launch: timeline construction, concept generation, initial design and quoting, final design for manufacture, manufacture and testing, packaging construction, and product launch.
- Attend consumer research and convert feedback and marketing requirements into new products.
- Work closely with internal and external industrial designers to meet aesthetic and ergonomic requirements.
- Directly communicate with oversea suppliers for tooling, manufacture, assembly, packaging, and testing of parts.
- Travel to and directly work with local plant for manufacture, final assembly, and testing of parts.
- Work closely with model makers for pre-tooled sales samples.
- Use SolidWorks to provide product renderings for sales and marketing.
- Improve existing designs to address customer complaints.

- Designed plastic injection molded parts and stamped metal parts for pilot headsets.
- Developed and performed mechanical tests on part assemblies.
- Operated an Objet30 Pro 3D printer for Beta prototyping.

- Provided consultant services for numerous public transportation authorities.
- Reviewed drawings, designs, manuals, and technical specifications.
- Assisted in the procurement of train car maintenance manuals.

- Assisted in the design and prototyping of electro-mechanical devices, primarily for use in military standoff chemical detection.
- Created CAD prototypes of various hardware such as mounting brackets.
- Redesigned layouts for weather-proof, military grade systems.
- Developed wiring diagrams in accordance with military specifications.
- Designed new schematics and board layouts based on electric principles and product datasheets.
- Altered circuit schematics and boards.
- Developed and tested installation procedures and user guides.
- Wrote detailed documents for both technical and non-technical audiences.
- Presented technical information to non-technical audiences.