Matt Johnson

Member of newly created additive manufacturing team, working with current project teams to utilize additive manufacturing to help achieve project criteria including cost, quality & timing targets.
- Manifold (SLA): Minimized BOM complexity, reduced cost and time to market through implementation of AM principles. Benefits: failure point reduction, internal passages (64% increase in activation airflow), 68 part reduction, usability improvements made possible only through additive
- Heat Sink (DMLM): Optimized fin design for thermal performance (16% increase in efficiency) through FEA & taking advantage of Additive capabilities direct print eliminates post processing
- Probe Head (Direct Write): Developed technology to print 3-D electrical traces, eliminating 30% scrap rate in current process reduced programming time 80% utilizing CAM experience
- Sensor (HP MJF, SLS): Realized cost (tool elimination, material volume: 58% reduction) & time savings (lead time: 13 weeks reduced to 2 weeks) and performance tuning (customized internal path)
- Additive Tooling (FDM): Designed 2 thermoform tools, optimized for AM 94% tool cost reduction
- Mentored product teams on principles of DFAM
- Mentor and train peers in advanced CAD techniques and skills
- Supported ventilator manufacturing line during COVID ramp up to quadruple production (R860, Mixed Model, Tech 8, & California lines) helped train new hires

Research & Development Research & Development - Prototype Engineer Lead for creating challenging production CAD geometry, prototypes, designed and fabricated tools (LSIM, FRP, Additive tooling) for short run production solutions, including:
- Luke Arm: Robotic prosthetic arm, offers an immensely more capable arm to amputees
- Mobius Mobility (iBot): mobility solution that truly brings dignity back to disabled people while also giving unprecedented mobility (displayed in Toyota's 2018 Olympic campaign) 25% weight reduction in base parts, allowing for extended battery range
- Slingshot: Water purification machine, 2012 Olympic display by Coca-Cola & documentary film
- Developed and managed new development lab
- Designed a new space of ~18,000 sq. ft to be efficient, clean, & safe
- Managed contractors to deliver build out of new space
- Managed lab staff and implemented capital projects to increase capabilities of lab
- Closely involved with Dean Kamen on many projects inside & outside of work relied on by Dean heavily to produce prototypes for critical customer meetings, often with extremely tight deadlines

Managed development lab and responsible for production CAD models, production runs & prototypes, developed and utilized Additive Tooling
- Implemented short run production of products & prototypes on Datron 2 way radios, Voxtec translation devices, Dynavox speech device, Circulite functional demonstration display
- Created models with complex geometry for final products, estimated time & cost quotes for customers
- Managed Development lab & additive equipment (Polyjet, FDM)

Responsible for designing and fabricating aesthetic and functional prototypes, DFAM
- CAD design, detailed CNC machining, quick turnaround of high quality, functional prototypes
- Involved in the submission of multiple patents