© Charles Mallory - Last Updated Friday, November 30, 2018


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Charles Mallory

Teaching Page

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Software

Experienced with Word, Excel, Access, Visio, PowerPoint and Outlook.  Created complex spreadsheets utilizing VB Scripting and advanced features with Excel.  Produced sophisticated presentations with automation to provide effective communications with PowerPoint.  Analyzed large data sets to automate data mining and save data for process trending using Access.  Utilized Access as front end to mine SQL data. Created flowcharts to represent process, for failure analysis and to outline structures. Managed multiple email accounts utilizing Outlook.  Utilized Outlook to create schedules and reminders.

Microsoft Office

Utilized SolidWorks to document product, tooling and fixtures.  Created 3D drawings and assemblies utilizing the features of SolidWorks to verify concepts, tolerances and feasibility.  Exported SolidWorks files to MasterCam, MakerBot and 3d printers.  Experienced in using equations to allow for quick modifications of drawings.  Designed custom fixtures that can be 3D printed but not machined to meet design requirements.  Designed custom fixtures for MRI testing, Electrical Isolation, Marketing approval and new products.

SOLIDWORKS

Processed images to meet customer needs.  Cleaned images and converted to appropriate images for other software programs.  Refined and created specialized images for various customers

Photoshop / Paint.Net / Inkscape

Tools I am versed with...

Hardware

Experienced in precision metal machining.  Horizontal and Vertical Mills, Engine and Turret Lathes, Surface Grinders, Shapers, Gear Hob, Blanchard Grinding, Armature Balancing, Heat Treating and Plating, Drill Press, Bench Grinders, Pantograph Engraver and Scribing and Band Saws along with welding bands for band saws, sharpening of drill bits by hand using bench grinder without fixtures.  Experienced in wood and plastic machining using Routers, Circular Saws, Jig Saws, Reciprocating Saws, Miter Saws, Belt Sanders, Hand Drills, Planers.

Machinist

Experienced with Ceramic and FR4 (organic) substrates.  Experienced with designing and specifying multilayer Hybrid circuits to meet Mil Std 883, JDEC , IPC Class I and Space requirements.  Experienced in producing ESD resistant assemblies.  Proven track record with SMT design, manufacture and rework, DIE screening, Wire Inspection and process verification by providing unused connections that are pulled to verify assembly.  Experienced with RoHS assemblies, moisture getters, hermetic packaging.  Experienced with Medical Devices, Commercial Devices and low voltage access control equipment.

PCB/PCBA Design Manufacture, Failure Analysis and Repair

Wet chemistry, microscale analysis and instrumental analysis.  Production of trimethyl triazene starting materials in molar scale to organic analysis to microliter analysis.  Paper Chromatography, carbon NMR, UV Vis spectroscopy, Atomic Emission, EDX analysis, quantative and qualitative analysis.  Atomic absorption, creation of reagents, creation of unknowns for students.

Chemical Analysis

Toys

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EKG Recorder

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Home Alarm System

Created programs to monitor and record data into SQL database.  Developed Poka Yoke programs to automate equipment operations.

LabView

Implemented SPC for Class III Implantable Medical Device production.  Automated data entry into Infinity QS and configured email notifications.  Implemented automated detection for processes reaching control limits which allowed proactive correction prior to processes reaching specification limits.

Infinity QS

Created 2D drawings to meet GDP requirements.  Created tooling and product drawings.  Experienced in 2D AutoCAD processes.

AutoCAD

Utilize various programs to create web pages for College students and faculty support.  Maintained and updated data in timely manner to support students and faculty.

Web Page Development

Adobe Acrobat forms

Arduino programming

Assembly Language for Motorola microprocessors

Automated pass-fail data programs

Barcode generator

Barcode Wiz

BarTender

Boolean logic

Component documentation

Device documentation

Documentation to GMP QSR

DMAIC

EE designer

FileMaker Pro Installation

FrontPage

IC layout design early tools

Infinity QS

IP printing

iPhone programming classes

Laser Star software integration with Excel

Lean Processing

Libre office

Linux

Lotus 123

LPR printing

Metrology procedures

MediaWiki

Motorola scanner programming



MP3 editing

MP4 editing

MySQL Server and clients

Novell Networks installation and administration

ODBC programming

Pascal

PostScript

Python

Raspberry Pi programming

Reverse Polish Notation RPN calculations

Scripts

Seagull software

Sequel Scripts

Sky mapping software

SolidWorks classes

SPICE for electrical analysis

Statista

Statistical analysis classes

Symbol scanner programming

Symbol Scanner to Laser Star

the other database software

Unix

Validation plans

VB programming to Laser Star

VB scripting to Laser Star

VB Scripts

Verification procedures

WebPlus

What if analysis using Excel

WordPerfect


Miscellaneous

35mm Motion Picture Cameras

AC-DC converters

Analytical chemistry

Atomic absorption spectroscopy

Automatic Transmission repair

Automotive air conditioning installation, repair, replacement and maintenance

Automotive brakes repair, upgrade and replacement

Automotive Repair

Band Saws

Bench Grinders

Blanchard grinder

Brazing using a gas torch

Cell phone battery replacement

Cell phone repair

Cell phone screen replacement

Circuit protection

Cisco AP balancing

Cisco WIFI AP Placement above ceiling tiles for cosmetic appeal

Cisco Wi-Fi internet installation for business with multiple AP.

Cognix Cameras and automation

Coax wiring

Curve fitting for data (linear, exponential, Weibull, Log, Polynomial and bathtube

Curve fitting programmed using a PDP-11

Datamatrix laser etching

DC-DC converters

Deburring of intricate parts

DVM for simple circuits

Engine Lathe

Engine rebuild and repair

Engine replace water pump

FDM printers

Fluoroscopy

Forklift training and usage

Freezing pinpoint depression apparatus

FTIR Spectroscopy

Gauss measuring of magnetic strength

GC Hotwire purity detection

GC Mass Spec

Hall effect sensors; linear, hall switch, power driving output

Handsaws

helium leak detector PCB

High vacuum systems

Home alarm wiring

Horizontal Mill


Inductor creation with driving circuit to magnetize BaFe cards

IR Spectroscopy

Laser automatic etching of unique serializes

Laser etching

Laser printers

Linear converters

Logic analyzer for Real Time Analysis of code

Low voltage data wiring

Manual Transmission repair, clutch plates replacement

Mass Spec

Mass Spec analysis of materials

Microcontroller design

of helium leak detector

Oscilloscope usage for design and fault detection

Pantograph engraving and scribing

PC repair

PCB design

PCBA design and assembly

Power Supply repair and HiPOT testing

Prussia printers

Reflow laser welding

Refractometer to measure the index of refraction of chemicals

Re-Plumbing of single family homes

Re-Roofing of single family homes

Resistance welding

Re-Wiring of single family homes

RJ11 telco wiring

RJ45 ethernet wiring

Router for wood shapes

Scanning Electron Microscipe

Silver soldering using a gas torch

Soldering PCBA repair to IPC 600 series standards, Mil 883 standards JDEC standards

Speaker wiring

Sputtering equipment

Sputtering processing

surface grinder

Surface Grinders

Table saw

Tre machine

Turret Lathes

UV visible Spectroscopy

Vertical Mill

Video monitor repair

Wirewrap prototype circuits

X-Ray Inspection


Miscellaneous

Early adopter of FDM printing for models from SolidWorks.  Built Prusia i3 from scratch and determined that output is feasible for customer approvals prior to machining.  Implemented MakerBot printers for Engineering, Manufacturing Engineering, Industrial Engineering, Manufacturing, Marketing and Sales use.  Enabled concepts and designs to fail fast to enable success for critical programs and high risk timelines.  Provided printers on corporate network to minimize scheduling and overhead costs to allow users to print from their desk.

FDM Printing