Matthew Cassabaum
Pittsburgh
Summary
Experienced mechanical engineer with a strong foundation in engineering principles and a proven track record of fostering effective collaboration among diverse teams. Skilled in applying technical expertise to drive innovative solutions and optimize operational efficiency. Demonstrated ability to effectively communicate complex ideas to both technical and non-technical stakeholders. Results-driven professional committed to delivering high-quality work and exceeding project goals.
Overview
7
7
years of professional experience
Work History
Senior Mechanical Engineer
Form Energy
12.2024 - Current
- Led comissioning of new manufacturing line as design owner, increasing yield by 90% while maintaining production throughput
- Collaborated with suppliers to ensure parts were designed to achievable tolerances while ensuring part functionality
- Developed manufacturing requirements to ensure product met system level performance and durability targets
- Worked with a diverse cross functional team to determine ideal design parameters for second generation product
Mechanical Design Engineer
LiveWire EV
08.2022 - Current
- Re-designed existing ~30V Battery module to reduce scrap, and remove $70 in cost
- Developed next generation battery architecture with ~200v cell to pack module, reducing part count by 50%
- Mentored junior engineers in proper engineering practices such as tolerance stacks and DFX, as well as providing guidance on internal systems/processes
- Conferred with EHS and Advanced Manufacturing to determine requirements for safe handling and assembly of new high voltage battery modules
- Designed several new accessories utilizing knowledge of sheet metal and carbon fiber manufacturing techniques
- Engaged with suppliers to solve critical production-gating quality issues in a timely and cost-effective manner
- Collaborated with members of quality, supply chain, and supplier to efficiently progress parts through PPAP to authorization
- Utilizing knowledge of manufacturing processes, developed components that minimized NRE as well as component cost and lead time
- Acted as a lead test engineer, carrying out DOEs to find an optimized solution to key regulatory certifications
Design Engineer
Milwaukee Tool
09.2020 - 08.2022
- Designed the world's first cordless air hammer (USPTO #20220371172)
- Devised work instructions to benchmark competitor tool life
- Performed math model simulations to optimize tool parameters, increasing tool performance by 100% while maintaining tool size and weight
- Led cross-functional project meetings to align on goals and paths forward
- Designed and built a test fixture to accurately measure real world performance of a tool
- Worked with customers to develop product specifications and align on product tradeoffs
- Utilized a phase-gate process to evaluate and present progress towards achieving project goals
Engineer
ADM Optics
09.2018 - 12.2019
- Interfaced with a key supplier, helping to develop their knowledge and capability in a new manufacturing process, ensuring high quality and cost effectivity
- Diagnosed and resolved supplier quality issues, reducing reject rates from 75% to
- Planned and implemented training programs to enhance supplier quality control
- Supported projects from conception to launch: initial design, rapid prototyping, manufacturing support, product qualification, and final inspection
- Redesigned existing aluminum products in titanium, performing strength of materials/stress calculations to reduce weight by an average of 40% while maintaining or increasing strength
- Designed and produced electro-mechanical fixtures to automate test cycles for optical devices
Education
Bachelor of Science - Mechanical Engineering
The University of Tulsa
Tulsa, OK05.2018
Skills
- 3D & 2D Cad - Solidworks, Creo, NX
- Excellent written & verbal communication
- Microsoft Office - Word, Powerpoint, Excel
- Supplier support and development
- PLM Software - Windchill, Teamcenter, Arena
- Risk assessment and mitigation
- Product development and optimization
- French Language - Conversational
- Junior employee guidance
- Requirements Definition
- Test plan development and execution
- Intercultural Awareness
- Design for Excellence
- Project Management
- Rapid Prototyping
- Leadership
- Failure Analysis
Timeline
Senior Mechanical Engineer
Form Energy
12.2024 - Current
Mechanical Design Engineer
LiveWire EV
08.2022 - Current
Design Engineer
Milwaukee Tool
09.2020 - 08.2022
Engineer
ADM Optics
09.2018 - 12.2019
Bachelor of Science - Mechanical Engineering
The University of Tulsa
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