Brian B JohnsonDesigner, Engineer

Brian B. JohnsonDesigner, Engineer

202 N ST #3Boston, MA. 02127617.834.5045contact@brianbjohnson.com

I am a passionate designer and mechanical engineer looking for a challenging, creative career opportunity. With a broad background that includes extensive experience in military, medical, industrial and consum-er product design, I add a unique skill set to the product development cycle. I have continued to expand my knowledge base by educating my-self in the use of new materials, processes and human-centered design thinking through the pursuit of creative personal projects. I have also actively sought out technical and creative surroundings by joining the Artisan’s Asylum in Somerville, MA. I am seeking a position that will challenge me technically and creatively in a collaborative work environ-ment surrounded with like-minded coworkers who enjoy what they do.

U.S. Army/Department of DefenseWeapons’ Effects Modeling and AnalysisAberdeen Proving Grounds, MD

My first experience outside the academic world was with the U.S. DoD Army Materiel Systems Analysis Activity. As a Mechanical Engineer for the Army, I developed physics-based models to perform statistical analyses of complex indirect fire combat situations. Weapons interactions in modern urban environments include many variables previously not encountered in open terrain combat arenas. With improved computing capabilities, more detailed models can process much larger amounts of data providing levels of resolution previously not possible. Providing these models with intelligence data, building construction information, and target vulnerabilities yields a very important tool for the military in planning operations in urban battlefields.

• Developed and used statistical models for calculation of delivery error, aiming, and effectiveness of artillery munitions, based on physics, meteorology, and material properties.

• Project lead for design and development of innovative methodologies to predict effects of weapons against targets in urban environments, involving fragment degradation due to air drag and penetration through materials.

• U.S. technical lead for NATO software design modeling the effectiveness of weapons against targets based on various factors, including multiple guns and munitions as well as meteorological and other natural effects

• Obtained and currently have government security clearance at level Top Secret/SCI, Secret, and NATO Restricted clearance.

• Performed work with contractors as needed and trained to be a Contracting Officer Technical Representative for projects involving outside defense contractors.

• After less than two years, was reviewed to be one of the top two analysts in the Branch consisting of 30 to 40 coworkers.

Mechanical Engineer10.2004 - 08.2007

01 PROFESSIONAL

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Mechanical Engineer,Product Manager08.2007 - 08.2009

Anholt Technologies, Inc.Composite Medical ProductsAvondale, PA

During this time I transitioned into the medical product design community. Having a strong desire to be more involved with design, I moved into a mechanical design engineer position with Anholt Technologies/Q-Fix Systems. Anholt Technologies is a medical products company that designs and manufactures com-posite material products used in the medical field in radiology, radiation oncology, and patient position-ing. Medical products designed and manufactured by Anholt Technologies include foam core carbon fiber composite structures, composite panels, molded parts, injection molded parts, and machined parts. All products must meet specific structural and functional requirements, regulated by the FDA and must follow ISO standards.

• With Anholt, I led design efforts of carbon fiber composite medical products for Radiation and Oncology treatment. This included all initial product design work, prototyping, testing, and manufacturing efforts for a large number of products.

• As a design engineer my main responsibilities were new product development, however in the small business environment I was also involved with process engineering, manufacturing engineer, research and development, and general business improvement responsibilities.

• I was tasked with continuous research and development of new products, new processes, and the use of new materials.

• Managed new product development, including personnel, vendors, and production processes to deliver projects on time with high quality and proper documentation.

• Undertook Improvement of production processes and equipment to bring business into larger production quantities, following lean manufacturing ideology while maintaining stringent ISO and FDA compliance.

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Mechanical Engineer,Project/Program Manager08.2009 - today

Globe Composite SolutionsMilitary and Medical Composite ProductsRockland, MA

I have since continued my design endeavors with Globe Composite Solutions in Rockland, MA. By moving to another small company, I was able to stay involved with all aspects of the design process from sales and dis-covery work, prototyping and design, to project management and manufacturing. As the lead design engineer and project manager for all military and medical products, I have had designed over 50 products in three years, including next generation sound-absorbing panels for submarine sonar array systems, carbon fiber supports for onboard missile battery enclosures, and lead replacement components for baggage x-ray systems. I work to develop new materials and processes focusing on the use of liquid cast polyurethane materials which make up the majority of Globe’s products.

• Led the engineering development of high performance seals using high-strength polyurethanes bonded to titanium for long life submersible applications. This project included the development and manufacture of ten different deliverable seals to meet prime contractors’ project deadlines.

• Medical projects include developing castable composite with x-ray blocking properties to replace lead in current imaging products.

• Other projects involve the use of carbon fiber composites for aerospace applications, urethane based components for application in mechanical systems of wind turbines, and high-strength carbon fiber based hardware for medical imaging products.

• For all projects, I am responsible for product design, tool design, prototyping, managing tooling fabrication, testing, transfer to production, and improvement of processes during production.

• Responsible for research and development of new products, new processes, materials, and use of new materials.

• Technical lead for SBIR proposals. I have submitted four proposals between 2009 and 2013.• Project management responsibilities include coordination of personnel, vendors, and production

processes to deliver projects on time with high quality and proper documentation.

01 PROFESSIONAL

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Founder, Owner, and Lead Designer11.2007 - today

theUncommonGreenFurniture, Home Accessories, and Custom ArtBoston, MA

In 2007 I began my own private design company, theUncommonGreen. Searching for a way to express myself beyond the products I was creating at work, I began designing and creating functional products that I could not find on the market to sell through my own business. As the founder and lead designer of theUncommonGreen, I have researched and applied new skills, including package design, business strategy, marketing techniques and a mul-titude of other facets and details of design. In 2011, I introduced eight new products to my website, and in a nine-month span, I sold nearly 1,000 units of my math-inspired Pi Bottle Opener. 2012 brought the release of over a dozen new products and twice the revenue of 2011, largely spurred by the release of my new Street Maps Glassware product line. I have had widespread press in-cluding in the Washington Post and will be featured in the print artists catalog UncommonGoods this Fall and Winter, 2013. The Pi Bottle Opener and Street Maps Glassware exemplify the many projects I have been working on, all of which have brought me great excitement and the confidence to become more deeply involved with design, as I have learned that it is a part of who I am and what I want to do each day.

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Patient Treatment SystemsEngineering/Project ManagementAnholt Technologies/Q-Fix Systems

With Anholt/Q-Fix I was the lead design engineer and project manager for radiation oncology and patient positioning medical system products. Part of my product experience is shown; a family of medical devices allowing for interchangeable treatment platforms in use for various types of cancer treatment.

Product Improvements

Optimizing construction to improve performance was critical to minimize “ghosting”, which was the projection of the product in x-ray images.

02 MEDICAL PRODUUCTS

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Mechanism Design

Latch mechanisms were designed to allow for the use of modular inserts. This provided a standard base with attachments which could be quickly changed for different treatments allowing for flexibility based on patient needs.

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Industrial Gearbox RedesignEngineering/Project ManagementGlobe Composite Solutions

I have been project manager and lead design engineer for medical, military, and industrial products for Globe. This example illustrates the design efforts involved in the redesign of an existing aluminum gearbox housing assembly.

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Initial project research stages included site visits to plants using the existing products and investigating other product lines of the customer and competitors in the field.

Once I had a strong understanding of the product, I determined specific performance requirements that were needed. All of these inputs were used in the initial design of the new gearbox assembly.

Project Scope

03 PRODUCT DEVELOPMENT

I performed chemical exposure testing based on a typical in-service environment to determine degredation of material properties.I also performed initial analysis of thermal compatability to ensure the materials selected would perform adequately based on the design requirements.

Material Compatibility

I sketched initial concepts to begin exploration the form of potential new designs.

Concept Development

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A thermal analysis was performed to compare the existing design to the new composite design. This was used as a prediction of performance for lifetime of internal housing lubricants and helped in explaining fundamental design differences to the customer.

Thermal Simulation/Analysis

Finite Element AnalysisFinite element analysis was then performed to determine design viability and compare factor of safety to industry standards including material degredation extrapolations over the lifetime of the product.

03 PRODUCT DEVELOPMENT

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The final design delivered to the customer included initial product files of the new housing assembly, finite element analysis results, and a thermal analysis comparison of the new composite design compared to the existing aluminum parts.

In addition, a second phase of the project was outlined including intial mold design, final production costs and schedules, and preliminary molding partners in various world markets based on customer supply chain requirements.

Deliverables/Next Phases

Mold Flow Analysis

Mold flow analysis provided feedback to allow for design optimization prior to approval of the final part design. This analysis resulted in modification of wall thicknesses in different areas of the part. Final optimization of the part will be performed during first shots of the first article molded components.

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Composite Sortation SystemProduct Development and Mechanism DesignGlobe Composite Solutions

A large Asia-based airport logistics solutions company contracted Globe to develop a next generation baggage sortation system for their airport baggage handling offerings.The sortation system maximized the use of composite materials and advanced engineering polymers to reduce assembly components and minimize costs. The final deisgn offered a lightweight, low-noise solution.

Extensive research was done on existing competition sortation systems. My previous experience with composite sortation system design for the USPS gave a strong base platform for this research.Existing systems drive systems, control requirements, and tilting mechanisms were investigated through documentation research and physical product inspection when possible.

Research/Benchmarking

Maintenance Information Description of Systems Equipment

© FKI Logistex A/S 2007 24 Jan 2007

Sorter System Sorter components

M2.2.5 - 26/109

(L:\DOKUMENT\ATS\MC\6904CHT3\_OM_MANUALS\M2\M02_2_05.DOC)

10. COVER BETWEEN TRAYS To prevent straps, small items and the like from falling down into the gap between the

trays - which could damage the sorter - the trays are fitted with a two-part cover

consisting of a front and a rear cover. The cover fills the gap between the trays and is

pressed together on the inside of the curve when the carts pass through curves. When

the train of carts realigns along straight stretches, the cover returns to its initial position

by means of two springs.

Fig. 10-1 Sorter with cover between trays 1. Tray

4. Spring 2. Rear cover

5. Front cover 3. Rear support

6. Front support

The rear and front covers as well as the supports are made of plastics. The springs are

stainless steel springs. The front cover and support are fastened to the tray front by

means of four countersunk screws. The rear cover and support are fastened to the rear

end of the tray by means of four countersunk screws. Both springs are placed on the

rear part. The front cover can turn around a guide pin placed on the support. The turning

movement is controlled by a curved track in the front cover, which turns around another

guide pin placed on the support when the train of carts enters and exits a curve (Fig.

10-2).

MECHANISMS04 MECHANISMS

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Component design included mechanism design to accomodate for electronic motor tilting operation and interaction with induction power supply and system control interaction.Concepts were developed in this stage to accomodate all requirements.

Ideation and Mechanism Design

Following development of concepts the best concept based on cost, performance, and customer inputs was selected and fine tuned.Multiple manufacturing/processing techniques were leveraged to optimize design costs and minimize assembly components. The following processes outline production methods to be used for full system production.

• RIM molding• Inection Molding• Centrifugal Casting• Open Casting• Conventional machining• Diecasting• Thermoforming

Design for Manufacture

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Modern Home GoodsBranding, Engineering, Product DevelopmenttheUncommonGreen

I started theUncommonGreen as an exploration into consumer goods using novel materials and processes. This has been an exploration into areas typcially not encountered in my other engineering career experiences and has exposed me to many different aspects of consumer product development.Shown are a number of products that I developed, marketed, and am currently selling in numerous locations throughout the country. I have had success in continued sales and increased volumes as well as press in many media including the Washington Post, the Huffington Post, and Uncommon Goods.

Pi Openerlaser cut steel and stainless steel, tumble media finishing

05 CONSUMER PRODUCTS

Custom Furnituresteel base with reclaimed barnwood top 13

Concrete Explorationcreated products with concrete for grooming and home use

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theSwizzleStikDevelopment of a manufactured cocktail tool

Street Maps Glasswarerotary laser etched from hand made vector maps

Thank You