Frank mayo aircraft design engineer flight controls–crew station-mechanical systems-mechanisms far 23, 25 & 29 prototype, certification & military




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FRANK MAYO
AIRCRAFT DESIGN ENGINEER

FLIGHT CONTROLS–CREW STATION-MECHANICAL SYSTEMS-MECHANISMS

FAR 23, 25 & 29 PROTOTYPE, CERTIFICATION & MILITARY

Permanent Address: 536 Maple Street, Brevard, NC

Phone: 828-553-9168

mbgator1@gmail.com

Experience Summary:

Forty years of aircraft design specializing in STC’s, prototype, certification and military aircraft. I have been an engineer and design lead on numerous general aviation and military programs responsible for configuration, mechanisms, flight controls, systems, cockpit architecture and flight test equipment design.


Special Skills:

Design of FAR 23 & 25 flight controls, mechanical systems, cockpit/crew station and the writing and implementation of static and functional test plans. Canopy and escape system design and incorporation of fly-by-wire controls systems.


Accomplishments:

Designation as Mechanical Systems SME and consultant to The Wall Street Journal and another leading national publication on matters of aircraft development, flight controls and mechanical systems.



Aircraft:

  • McDonnell F-4, F-18, F-23 & A-12

  • Lockheed F-22 & F-35

  • NGC E-2D & T-X Trainer

  • Bell V-22

  • Gulfstream G-IV & G-V

  • Sikorsky Blackhawk/Seahawk & CH-53

  • Boeing 787

  • Airbus A400M

  • Dornier 328

  • Piper Meridian, Piperjet & Altaire

  • Toyota Advanced Aircraft

  • Textron Scorpion/Cessna Next Generation

  • Virgin Galactic Spaceship/Mothership


Computer Aided Design Systems:

  • CATIA V4 50,000 hrs.

  • CATIA V5/V6 8,000 hrs.

  • Unigraphics versions 12-18 2,000 hrs.

  • UG NX2-NX5 & NX10 8,000 hrs.

  • CADD 10,000 hrs.


Education:


Work History:

June 2015 – Present

NORTHROP-GRUMMAN CORP., El Segundo, CA

MECHANICAL ENGINEER LEVEL 4 – SME CANOPY INTEGRATION


Responsibilities are development of the cockpit and design oversight of the canopy, mechanisms, escape system, crew station, flight controls and integration with the Forward Fuselage Structure on a proof of concept aircraft. I am charged with overseeing the design of a crew environment that adheres to all JPATS requirements. Work performed with CATIA V5 and UG NX10/Teamcenter.
December 2014 – June 2015

TEXTRON, Wichita, KS

FLIGHT CONTROLS SIMULATOR DESIGN ENGINEER
Responsible for empennage flight controls simulator design on two next generation Cessna business aircraft. Layout of fly-by-wire rudder and horizontal stabilizer pitch system actuation. Work performed with CATIA V6.
June 2014 – December 2014 Unemployed
March 2013-May 2014

VIRGIN GALACTIC/THE SPACESHIP COMPANY, Mojave, CA

FLIGHT CONTROLS DESIGN ENGINEER
Responsible for analysis and re-design of yaw, pitch and roll systems and associated actuation components on the FAR 25 SS2 Spaceship in a rapid prototype environment. Duties included ensuring that Scaled Composites designs conformed to the FAR’s and that the vehicle could withstand a 2,000 lb. MTOW increase. Work performed with CATIA V5/Agile.
Feb .2012-March 2013

TEXTRON/AIRLAND, Wichita, KS

PRINCIPAL FLIGHT CONTROLS DESIGN ENGINEER
Responsible for development of flight controls, flaps, flap actuation and cockpit configuration for a prototype FAR 23 high performance aircraft. I had oversight of the JPATS compatible cockpit design through surface control systems design by a 6-member team. Work performed with CATIA V5/VPM.
Dec. 2011-Feb. 2012

GULFSTREAM AEROSPACE, Savannah, GA

FLIGHT CONTROLS DESIGN ENGINEER


Investigation of surface actuator install/remove clearances on the next generation aircraft. Work performed with CATIA V5.
Feb. 2011-Dec. 2011

PIPER AIRCRAFT COMPANY, Vero Beach, FL

FLIGHT TEST EQUIPMENT DESIGN LEAD ENGINEER
Responsible for development, manufacturing and installation of flight test equipment for a FAR 23 production jet. I oversaw design of the nose boom, pilot emergency egress system, blow-off door and spin chute. Work performed with UGNX-5/Teamcenter.
Oct. 2010-Feb.2011

AAR CORP., Goldsboro, NC

MECHANICAL SYSTEMS DESIGN ENGINEER
I designed onboard cargo handling mechanisms, pallet latches and aerial deployment systems on the Airbus A400M aircraft. Work performed with CATIA V5/Smarteam.

Nov. 2009–Oct. 2010

SIKORSKY AIRCRAFT, Stratford, CT

FLIGHT CONTROLS DESIGN ENGINEER


I was assigned to the Blackhawk & H-53 helicopter Flight Controls Groups responsible for re-configuration of hydraulic manifolds, coordinating revisions with manufacturing and resolving non-conformance and rigging issues. Work performed with CATIA V4-V5/Enovia.
May 2009–Nov. 2009

BOEING COMMERCIAL AIRPLANE CO., Everett, WA

MANUFACTURING ENGINEER
I was assigned to the 787 as a Manufacturing Engineer. My responsibilities were investigation of control surface non-conformances and the writing of rig and de-rig procedures for flaps. Work performed with CATIA V5/Enovia.
Sept. 2006–May 2009

PIPER AIRCRAFT COMPANY, Vero Beach, FL

FLIGHT CONTROLS DESIGN ENGINEER
Responsible for design, manufacturing and installation of the flight controls for the FAR 23 PiperJet. My responsibilities included development of a side-stick controller, design of flaps, aileron, rudder and elevator controls and studies for incorporation of vectored exhaust, writing of functional test plans and the Pilot Operating Handbook. Work performed with UGNX-2 & NX-3
Jul. 2005–Sept. 2006

NORTHROP-GRUMMAN CORP., Bethpage, LI., NY

FLIGHT CONTROLS DESIGN ENGINEER
Responsible for modifying the hydro-mechanical flight controls on the E-2D Advanced Hawkeye. I designed mechanisms for control surface position indication and deployment of an in-flight antenna. Work performed with CATIA V4/Enovia.
Feb. 2005–Jul. 2005

LOCKHEED-MARTIN, Ft. Worth, TX

MECHANICAL SYSTEMS DESIGN ENGINEER
Responsible for development of the aerial refuel probe actuation mechanism for the F-35 Joint Strike Fighter. I designed the hydraulically actuated deployment mechanism and developed kinematic models to validate operating clearances. Work performed with CATIA V4/PDM.
Sept. 2001-Feb. 2005

TOYOTA AVIATION BUSINESS DEVELOPMENT OFFICE, Torrance, CA


FLIGHT CONTROLS DESIGN ENGINEER

Responsible for engineering of the flaps and flight controls for a FAR Part 23 aircraft. Designed an iron bird for controls and landing gear functional testing and wrote/implemented all functional test plans. Designed and flight tested various side-stick control concepts at Scaled Composites, Mojave, CA. Work performed with CATIA V4.


Jan. 2001-Sept. 2001

HONDA AIRCRAFT COMPANY, Greensboro, NC

DESIGN ENGINEER

Responsible for design of the control yoke; elevator and elevator trim controls for the FAR 23 Honda Jet and development of models for rework of the horizontal stabilizer and elevator. Work performed with CATIA V4.


Apr. 2000-Jan. 2001

NORDAM GROUP, Tulsa, OK


MECHANICAL SYSTEMS DESIGNER

Design of fuel system components, thrust reverser and nacelle on a Pratt & Whitney-Canada prototype turbofan engine. Work performed with CATIA V4.


Oct. 1999-Apr. 2000

GULFSTREAM AEROSPACE, Savannah, GA

DESIGN ENGINEER

Design of the G-IV prototype satellite communications radome that was incorporated into the production aircraft. Coordinated the manufacturing and installation at various completion centers and assisted with documentation for issuance of a Supplemental Type Certificate. Work performed with CATIA V4.


1998-Oct. 1999

PIPER AIRCRAFT COMPANY, Vero Beach, FL

DESIGN ENGINEER
I was responsible for design of the horizontal stabilizer and elevator on the FAR 23 Malibu-to-Meridian conversion. Work performed with Unigraphics version 18.
1997-1998

NORDAM GROUP, Tulsa, OK


SYSTEMS DESIGN ENGINEER


Design of nacelle doors, pylon and fire suppression systems on the Dornier 328 aircraft engine. Assisted with documentation for JAA certification. Work performed with CATIA V4.

1996-1997

GULFSTREAM AEROSPACE, Savannah, GA

DESIGN ENGINEER

I was responsible for design of G-V metallic and composite fuselage and engine pylon components. Work performed with CATIA V4.
1995-1996

LOCKHEED, Marietta, GA

MECHANICAL SYSTEMS DESIGN ENGINEER

Re-design of the F-22 aircraft horizontal stabilizer composite pivot shaft and elevator hydro-mechanical actuation mechanism. Modeling of components performed with CATIA V4.


1994-1995

AEROSTRUCTURES, Nashville, TN

STRUCTURES DESIGN ENGINEER
Re-design of the V-22 Osprey rudder, balance horns and rudder actuation system and conversion of the metallic ramp to an all-composite structure. Work performed with CATIA V4.
1993-1994

GULFSTREAM AEROSPACE, Savannah, GA

DESIGN ENGINEER
I originated models of flaps and flap tracks for the G-V aircraft. Responsible for design of the engine thrust strut, APU ram air inlet, wing-to-body fairing and associated structural components. Work performed with CATIA V4.
1975-1993

McDONNELL AIRCRAFT COMPANY, St. Louis, MO

SYSTEMS DESIGN ENGINEER
F-15 and F-18 structural design and feasibility studies for various stealth aircraft concepts. Designed and installed wing components and flight control actuation systems on the ATF-23 POC tactical fighter. Responsible for nose, leading edge design and radar box installation on the A-12 attack aircraft. I designed the wing fold mechanism on the FA-18 E/F aircraft. Work performed with CADD, CATIA V4 & Unigraphics.
Clearances:


  • DOD Secret (Inactive)

  • Air Force and Department of Navy Special Access (Inactive)



References:
Bob Geiger

Structures Engineering Fellow

Northrup Grumman Corp., El Segundo, CA

310-663-5490


Mark Buchholz

Structural Design Engineering Manager

Northrop Grumman Corp., Bethpage, L.I., New York

516-346-4561


George Feise

Wing Structure Engineering Manager



Gulfstream Aerospace, Savannah, GA

912-395-0778


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