Manufacturing Systems • Applications Engineering • Operational Analytics

Donald A. Sargent

Applications Engineer | Manufacturing Systems | Process Optimization

I solve real manufacturing problems by connecting design intent, production methods, tooling, automation, and operational data. My work spans mechanical design, CNC programming, fixture design, engineering workflow automation, FEA, and manufacturing analytics.

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Core Value

Design → Production

Experience bridging product design, manufacturability, tooling, and production execution.

Manufacturing Systems

Fixture design, CNC programming, workflow automation, process validation, and operational problem solving.

Data-Driven Improvement

Python, SQL, PowerShell, ETL-style workflows, engineering data organization, and manufacturing visibility.

Selected Results

~50% welding cycle-time reduction through fixture redesign

45 → 5 min machining cycle-time reduction

20% → <1% scrap reduction

10 U.S. patents across medical devices and LED lighting

Project Highlights

High-Temperature Structural FEA — Industrial Oven Systems

Solid Edge Simulation • Femap • NX Nastran

Performed iterative FEA studies on high-temperature industrial oven grate and support systems subjected to 30,000–50,000 lbf concentrated loads at approximately 1000°F. Evaluated deflection, stress concentration, load paths, and structural performance across grate-only, frame-only, and combined assembly models.

Automated Thermal Validation — STERIS

Instrumentation • Data Acquisition • Test Automation

Designed and implemented a thermocouple-based thermal validation system for medical sterilization equipment, improving repeatability and visibility into system performance.

Manufacturing Analytics Pipeline — Lanly

Python • SQL • PowerShell • ETL Workflows

Developed workflows to connect engineering files, ERP records, estimates, budgets, and labor tracking into operational reporting structures for estimate-vs-actual visibility.

CNC Automation & Fixture Optimization

CNC Programming • Vacuum Fixtures • Batch Processing

Designed vacuum-fixture and CNC workflow systems using fixture offsets, automated numbering logic, and batch processing to improve throughput and reduce operator involvement.

Technical Areas

Mechanical design, large assemblies, fixtures, tooling, and workholding
CNC programming, process development, and manufacturing optimization
FEA analysis, structural evaluation, and simulation-supported decision making
Python, SQL, PowerShell, SharePoint, ERP data, and engineering workflow automation
GD&T, DFM, process validation, instrumentation, and automated testing

Contact

Email: justdust@outlook.com

Phone: 440-251-2762

Website: dsarge.com