| calvin_toothaker_resume_-_mechanical_engineer.pdf |
objective
I specialize in bringing innovative tech products from concept to production with expertise in CAD modeling and finite element
analysis using SolidWorks. My holistic design approach emphasizes creativity, manufacturability, and ease of assembly. I have
designed complex mechanical systems for diverse applications, including industrial automation machinery, a seven degree of
freedom (7 DOF) collaborative robot, and an IP67, MIL 810F-standard industrial headset.
analysis using SolidWorks. My holistic design approach emphasizes creativity, manufacturability, and ease of assembly. I have
designed complex mechanical systems for diverse applications, including industrial automation machinery, a seven degree of
freedom (7 DOF) collaborative robot, and an IP67, MIL 810F-standard industrial headset.
skills
- Technical Skills: New Product Development, Design for Manufacturing/Assembly (DFM/DFA), Materials Selection, Prototyping,
Design of Experiments, Offshore/Contract Manufacturing Management, Vendor Communication, GD&T - Manufacturing Knowledge: Die Casting, Injection Molding, Sheet Metal, Weldments
- Software: SolidWorks (Expert in surfacing and FEA simulation), Empower PLM (Omnify), NetSuite, JIRA, Confluence, MS Office
- Leadership: Open Communication, Conflict Management, Ethical Decision Making, Fostering Trust & Respect
experience
Berkshire Grey , Bedford, MA
Principal Mechanical Engineer & Director of HW Engineering, 7/2018-present
Berkshire Grey builds solutions that combine AI and Robotics to automate fulfillment in retail, eCommerce, and logistics by transforming pick, pack, and sort operations.
Management:
RETHINK ROBOTICS, Boston, MA
Senior Mechanical Engineer, 8/2015-7/2018
Rethink Robotics designs and manufactures flexible and cost-effective collaborative robots
SONETICS CORPORATION, Portland, OR
Mechanical Engineer, 3/2011-2/27/2015
Sonetics Corporation creates wireless team communication systems for harsh high noise environments
SRS ENERGY, Philadelphia, PA
Lead Reliability Engineer, 9/2008-3/2011
SRS Energy is a start-up company which designs and manufactures aesthetically pleasing building integrated photovoltaic modules
ARIES ELECTRONICS, Bristol, PA
Product Engineer, 1/2008-8/2008
Aries Electronics designs and manufactures engineered to order test and burn-in sockets
Product Development Engineer, 2/2007-1/2008
Honda designs high quality automobiles is the world’s sixth largest automotive manufacturer
WOLF APPLIANCE CO., LLC, Fitchburg, WI
Reliability Engineering Co-op, 5/2005-12/2006
Wolf Appliance is a manufacturer of high-end residential kitchen appliances
ERIK’S BIKE SHOP, Madison, WI
Head Bicycle Mechanic, 3/2003-5/2005
Erik’s is a bike shop providing customers with consistent and knowledgeable bicycle service
Principal Mechanical Engineer & Director of HW Engineering, 7/2018-present
Berkshire Grey builds solutions that combine AI and Robotics to automate fulfillment in retail, eCommerce, and logistics by transforming pick, pack, and sort operations.
Management:
- Boosted morale through knowledge-sharing, technical training, and promoting collaboration
- Led quarterly hardware all-hands meetings to share technical innovations and retrospectives
- Delivered annual performance reviews and aligned individual goals with company priorities
- Held 1:1 meetings with 12 reports to ensure job satisfaction, identify improvements, and assist with career development
- Spearheaded project scheduling and task planning using Jira and MS Project; ensured alignment with company goals
- Conducted daily stand-up meetings with my team to identify progress and help remove any blockers
- Created product roadmaps based on feedback from both internal and external stakeholders
- Conducted FEA studies to determine strength and stiffness of welded structures
- Owned product development for 4 complex end of arm tools from requirements through manufacturing
- Designed test fixtures for accelerated testing of our components
- Developed V&V plans to ensure product quality
- Worked contract manufacturers leading to cost reduction and better designs for manufacturability and assembly
- Using Omnify (Arena) PLM, wrote engineering change orders to communicate a change to all affected stakeholders
- Conducted proof of concept reviews, preliminary design reviews, and critical design reviews
- Used 3D Printing and other common shop tools for rapid prototyping of new products
RETHINK ROBOTICS, Boston, MA
Senior Mechanical Engineer, 8/2015-7/2018
Rethink Robotics designs and manufactures flexible and cost-effective collaborative robots
- Expedited transition from prototype to mass production; focused on manufacturability, reliability, and cost reduction
- Leveraged SolidWorks for design and analysis of 7 DOF robot arm and a quick change tool plate
- Designed factorial experiments for verification testing
- Authored assembly instructions to uphold quality from our contract manufacturers
- Solved thermal issues in robot arm using custom design heat sinks
SONETICS CORPORATION, Portland, OR
Mechanical Engineer, 3/2011-2/27/2015
Sonetics Corporation creates wireless team communication systems for harsh high noise environments
- Launched 4 product lines, including a redesign of the company's flagship product, leading to 60% increased revenue
- Managed offshore vendors and manufacturers to ensure high product quality
- Focused on part function, DFM, DFA, and cost early in the design process
- Addressed a unique customer need, leading to the largest order in company history
SRS ENERGY, Philadelphia, PA
Lead Reliability Engineer, 9/2008-3/2011
SRS Energy is a start-up company which designs and manufactures aesthetically pleasing building integrated photovoltaic modules
- Managed testing for a thin film photovoltaic product, achieving UL certification of a building integrated PV roof tile
- Implemented a comprehensive testing program, including building out an in-house test lab
- Assisted in the setup of a manufacturing facility, from equipment qualification to process development
ARIES ELECTRONICS, Bristol, PA
Product Engineer, 1/2008-8/2008
Aries Electronics designs and manufactures engineered to order test and burn-in sockets
- Designed engineer-to-order chip scale, test, and burn-in sockets
- Automated CAD modeling for a major product line using VBA with SolidWorks, substantially reducing engineering time
Product Development Engineer, 2/2007-1/2008
Honda designs high quality automobiles is the world’s sixth largest automotive manufacturer
- Collaborated with R&D to ensure design feasibility early in vehicle development
- Addressed design and manufacturing issues during both product development and production stages
- Conducted investigations on the manufacturing floor to determine root causes of failures
- Reviewed 2D and 3D models in CATIA to identify any potential design weaknesses
WOLF APPLIANCE CO., LLC, Fitchburg, WI
Reliability Engineering Co-op, 5/2005-12/2006
Wolf Appliance is a manufacturer of high-end residential kitchen appliances
- Designed, built, and operated test fixtures to simulate life testing of new components
- Used Labview, and Fieldpoint data acquisition systems to track life cycle tests
- Programmed PLCs (Programmable Logic Controllers) using RSLogix ladder software
ERIK’S BIKE SHOP, Madison, WI
Head Bicycle Mechanic, 3/2003-5/2005
Erik’s is a bike shop providing customers with consistent and knowledgeable bicycle service
- Employed problem-solving skills to complete difficult bicycle repairs
- Trained new employees on the duties of a bicycle mechanic
education
UNIVERSITY OF WISCONSIN –MADISON, Madison, WI
B.S. Mechanical Engineering, Major GPA 3.59/4.0 1/2002 –12/2006
B.S. Mechanical Engineering, Major GPA 3.59/4.0 1/2002 –12/2006
awards and patents
- WO2023141260A1 - Systems for object processing with programmable motion devices using yawing grippers
- US20200338728A1 - Systems for maintaining vacuum hose life in hose routing systems in motion systems
- US11167411B2 - Quick-release mechanism for tool adapter plate and robots incorporating the same
- WO2021158770A1 - End-effector, programmable motion device and method of operating a programmable motion device
- US20160100238A1 - Ruggedizer for communications headset
- US9838776B2 - Restricted ball and socket joint for headset earcup
- USD790506S1 - Communication headset
- Solé Power Tile (Product designed while at SRS Energy) was awarded Popular Science ‘Best of What’s New’
- Solé Power Tile (Product designed while at SRS Energy) was awarded 2010 Edison Award, Gold
- Dean’s Honor List 2003 through 2006
