PCB Layout Engineer - Lead at Tesla

Archer

Staff PCB Layout Engineer

Zero Emission Recreational Organization

Founding President

At least two of my PCB layout designs are being used on SpaceX Starship in the Tesla supplied battery packs and motors. I'm happy to be aboard!

SpaceX

PCB Layout Engineer

Thirteen years total saving the planet one PCB design at a time. Recent projects include Semi and new generation Gate Drive Inverter (motor drive controller) PCB layouts, Cybertruck  High Voltage Controller PCB, Optimus Robot Sensor PCB and Megapack Power/Control PCBs among others.

Tesla

PCB Layout Engineer - Lead

At Joby I played a major role in redesigning the motor inverter drive control and power boards from rough prototype to polished and ready for production fully realized versions. Worked closely with Mechanical Engineer and Electronic Engineers to solve electrical, mechanical and structural issues. I also designed the Battery Manager Board (BMB) and high speed inter-unit communication board along with other rigid, flex and rigid-flex PCB designs. 

Complex PCB designs are like very challenging video game puzzles with tons of rules to be followed. After weeks and weeks of hard work solving the puzzle they make you do another one, over and over again! 

Still having fun solving puzzles.

Joby Aviation

Sr. PCB Layout Engineer

At Tesla I played an instrumental role in the initial development of the power and control electronics powering the 2013 car of the year, the Model S. I was involved in development of several systems for the Model S, X, Model 3, Tesla Semi and World Record Breaking Roadster 2.0 along with Tesla Energy Battery Storage Products. Millions of examples of my Tesla designs are in use throughout the world. 

Layout of high current, high voltage and high speed PCBs using Altium DXP.

Projects include:

Battery Manager Boards (BMB) used in Model S, Model X, Model 3, Model Y and Roadster 2.0. 
Inverter-power control boards that power the motors in the Model S, X, 3, Y, Semi and Roadster 2.0. 
Version of Model S Dashboard Instrument Cluster Display board. 
On-board Charger Power Board used in all Model S, X and used in Superchargers worldwide.
Electric Motor Power and Control Board for Model X Falcon Wing Doors.
Model S, X, 3 and Y High Voltage Junction Boxes (High Current Power Distribution) Board.
Single and Three Phase Contactor/Control Boards.
Mobile Charge Cable Power and Control Board.
Tesla Wall Connector Control Board.
Model S/X CHAdeMO Adapter Control Board.
Power Pack, Mega Pack and Powerwall BMB and Power and Control boards for stationary battery systems. 
System Test Boards.

Tesla Motors

PCB Design Layout Engineer R&D Power Electronics & Control

Design of custom and high volume power system PCBs and chassis. Projects included a large scale	
high speed, matched impedance control and power system PCB, and a miniature programmable battery charger / manager with mixed analog power and digital control circuits. Switch Mode and Resonant Mode AC-DC and DC-DC power supply PCB layout, schematic capture and mechanical chassis design. Researched new components and determined part availability. All designs met UL or medical safety approval.

XP Power

Sr PCB Design Engineer

Designed multilayer Multiple BGA PCB design used in a wireless video bingo system utilizing the Motorola DragonBall Integrated Processor with Flash and SRAM memory chips.

Rtronic

Contract PCB Design Engineer

Designed large pin count tester to IC DUT interface board.

Pier Electronics

Resonant mode power supply multi-layer PCB layout, Schematic capture and complex mechanical chassis design. PCBs included mixed SMD and thru hole parts. Researched new components and determined part availability.  Interfaced with customer’s design teams on mechanical layout. All designs met medical safety agency approval

Resonant Power

Sr Design engineer

Designed 10-layer, 5mil trace & spacing PCB.  High speed, high pin count BGA and very high pitch	SMD devices. For use in evaluating and verification of the Lexra LX4180 processor.
Collaborated on Schematic with circuit designer. Design functioned on power up with no changes.

Embedded Performance, Inc.

Switch mode power supply PCB layout, Schematic capture and mechanical design. Safety agency approved designs.

Digital Power Inc.

PCB Design Engineer & Mechanical designer

Designed Flip Chip / Micro BGA / Microvia flexible circuit, 25 micron traces typical.
	Created PC boards for revolutionary new semiconductor tester: High-speed Fine pitch surface mount designs using single ended and differential micro strip routing.
	Working prototypes utilized ASIC’s, Rambus memory and SCI networking on board. 
      Designed video processing IC evaluation boards for the University of N. Carolina virtual reality project. 
      Created complex schematics with minimal input from chief Engineers.
      Designed semiconductor DUT to tester interface boards.
      Designed distributed DC-to-DC power system.
      Hand assembled fine pitch SMD prototype boards using a microscope.
      Assisted in debug of PC board designs using oscilloscopes, signal generators, etc.
      Performed IC and component selection and purchasing.

Credence

Senior PCB Layout Engineer

Through-hole and surface mount printed circuit board design and documentation.
      Designed sheet metal rack mount chassis boxes for high power amplifiers.
      Schematic capture and wiring diagrams, Cabling design and documentation.
      Built prototype assemblies and printed circuit boards.
      Performed component and assembly sourcing and purchasing.

Nikon Precision Inc.

Electro - Mechanical Designer

Designed sheet metal chassis and packaging for entire product line.
      Designed DC power system for in-circuit emulator.	
      Created assembly drawings, wiring and interconnect diagrams.

Electro-Mechanical Designer

Designed plastic radar dome mock-up with 3D CAD program and utilizing laser cutting. Schematic capture of complex RF and digital P.C. boards and systems. Created detailed assembly drawings.

ARGOSystems

Designer / Drafter

Mechanical packaging design, Schematic capture, cable and harness design, created complex assembly drawings. Supervised prototype manufacturing team of up to 15 persons. Built prototype large scale automated test consoles and miniature electronic devices used in missile systems. Developed epoxy encapsulation techniques for high voltage products.

Quantic Industries

Technical Associate,  Lead of Eng. Lab,  Prototype Tech

Miniature medical video cameras, electronic, mechanical and optical assembly, repair and R&D

Dean Stanford