Francisco Javier Madera

Additive Manufacturing Engineer with Boeing's AMP Lab (Additive Manufacturing & Prototyping) Developing tensile testing procedures from scratch, following ASTM E8, to quantify strength allowables for additively manufactured metal components, with different alloys including titanium, stainless steel, maraging steel, and Inconel. Evaluating different airflow inlet designs on an EOS M400 using anemometer measurements to improve airflow uniformity across the powder bed surface and consequently, increase the uniformity of the resulting material properties.

Improving the design of 787 lavatories to enhance corrosion resistance through the elimination of water leak pathways, adjacent galvanically dissimilar materials, and material finishes and coatings. Design and conduct dedicated testing for the edge potting of honeycomb sandwich panels and preventative water ingress with different adhesives and sealants. Working through the design process with an international supplier and other internal stakeholders to ensure an integrated design which balances assembly time, install time, cost, and design improvements through dedicated analysis and reviews such as regular design reviews, DFMAs (design for manufacturing and assembly), PFD (process flow diagrams), and FMEAs (failure mode and effects analyses). Support global supply chain with detailed analysis of corrosion affected part numbers and most useful parts to stock in order to support airline customer AOG (airplane on ground) turnaround time.

Designed and modeled original equipment for transfer of nuclear molten salt containers and the de-cladding of highly enriched uranium (HEU) plates encased in stainless steel sheets within an argon gas flooded glovebox environment. Collaborated with multiple teams such as nuclear safety, fire safety, lab technicians, and machinists to analyze design feasibility, failure mode analysis, and prepare documentation for technical, functional, and operational requirements. Used PTC Creo to design a new and original vacuum distillation furnace to increase the fuel salt throughput of the UCl3 molten salt synthesis from 85% to more than 99% for the Molten Chloride Reactor Project (MCRE). Participated in many facets of the MCRE project including updating documentation such as the operational framework andwaste storage throughput plan for the fuel salt synthesis line, created the system architecture design for fuel salt containers, and developed requirements for the equipment, removal, and disposal system of the MCRE reactor.

Operated a DMG Mori Lasertec 12 Powder-Bed Fusion metal additive manufacturing machine, overseeing build file slicing and hatching, machine preparation, powder delivery, and post-processing machining and clean-up. Taught and assisted graduate students on other metals processing machines, such as cold/hot rolling on a rolling mill, ensuring proper thickness reduction ratios, speeds, and forces, as well as proper operation and cleaning of a furnace.

Supervised and assisted with engineering and management projects of a 40-member team, ensuring the use of good engineering practices and that projects were designed, validated, reviewed, and manufactured on schedule. Machined aluminum, titanium, and steel with CNC mills and manual lathes and welded structural frame tubes. Reduced wheel hubs weight by 3% and verified strength and durability using SolidWorks and Ansys FEA simulations.

Conducted three separate experiments for porosity, dimensionality, and surface roughness using a CMM machine, profilometer, and microscope to optimize process parameters on the SLM and DED hybrid metal additive machines. Led a collaborative project with an industry leader in finite element analysis software to develop a robust predictive model of how the heat and residual stresses deform a build during the welding of DED manufactured parts. Wrote the machining and welding CAM code with Siemens NX software for the repair of an out-of-spec General Motors engine die, using the DED metal powder additive process on a Lasertec 125 hybrid machine. Used topology-optimization to improve and print titanium medical implants on a laser powder bed fusion machine.

Drafted drawings and wrote documentation for the transportation, installation, and anchoring of a coil-fed laser blanking line for sheet metal, and used SolidWorks to design a safety backstop in case of metal coil strap failure. Designed new parts and updated 3D models of a medical flat mask machine, increasing durability of the machine and improving serviceability, through material selection and altering of the attachment and assembly methods.