Frank A Borke1734 17th Ave Greeley, CO 80631

(303) 917-7373Summary

• 25+ years of CNC Machining experience• Mechanical design and CAD designer for metal and plastics processes.• Molding of most plastics including laminates• Precision reverse engineering of objects and systems• Implementation of electromechanical systems including automated equipment,

robotics, PLC, microprocessor programming, support electronics and sensors• Black-smithing and heat treating• MIG/TIG and forge welding of Steels and Aluminum’s• Investment and sand casting of non-ferrous metals

• Implementation of TCP/IP networking, servers, and routers• Software programming fluent in BASIC, C variants, Assembly, Pascal,

FORTRAN for both OS software and embedded systems.• Electronics design, PCB layout and implementation of final systems.• Software experience: MasterCAM, Imageware Surfacer, TraceCUT, Photoshop

CS4, 3Dstudio, MS Office, MS Project, NI Labview, MS Visual Studio, Altium PCB Designer, Diptrace PCB designer, etc.

Education

Patternmaker apprenticeship for 4 years per Patternmaker’s union regulations at Master Pattern Inc. Journeyman since 1989

Machinist apprenticeship at Master Pattern Inc. Journeyman since 1992

1.5 years of selective classes in Psychology for personal interest.

Self-taught and working experience in:

Electronics design for the areas of communications, automation systems, magnetics, and power supplies.

Schematic capture, PCB layout and final testing of designed electronic systems.

Microprocessor programming, data acquisition system design and implementation.

Mechanical Engineering and Physics for that areas of High Pressure vessels, ROV’s, Deep sea oil components and automated machinery

Accomplishments:

6 Patents awarded and 4 pending approval through my work with a variety of companies.

“Best of show” and “Innovators Award” Award SEMA 2006 (Against GM, Chrysler and Ford Engineers)

Work Experience

Master Pattern, Inc. (Windsor/Greeley, CO) 2000 - PresentSole owner

• Job tasks require interaction with customers, budgeting and scheduling• Presentation and quoting of proposed projects • Management and oversight on all projects• Scheduling of multiple projects and engineering staff • Design of Electronics for various automated systems.• PCB layout and implementation of automated systems

Master Pattern, Inc. (Cincinnati, OH) 1985 - 2000 Full time employment and management

• Overseeing up to eight employees• Design, tool and set up customers with complete final production systems.• Managing a traditional manual, CNC machine shop, and fabrication of tooling

and automated machinery.

Master Pattern, Inc. (Cincinnati, OH) 1982 - 1985 Part time employment

• Responsibilities of an apprentice Patternmaker and Machinist

Vacuum form tooling and design experience.

• UTV enclosures and accessories for Bestop Inc.• Internal shipping pallet design and tooling for Ford, GM and Honda.• Carpet forming tools for Honda.• Supermarket display and product point of sale displays.• Cosmetic counter displays.• Blister packaging for Kenner toys, Duracell batteries, and others.• Bulk stackable storage part trays.• Hot tubs and covers for Form-all plastics.• Helmet shells for Adams, Lexington safety, Riddell, Bell.• Twin sheet forming of pallets for Hopple plastics.• Vacuum formed dashboards and accessories for Crown forklift.• Refrigerator interiors.• Vacuum formed paint masks.• Tri-fold POS. packaging

Tooling for vacuum forming.

• Pattern and Aluminum cast tooling.• Machined tooling from Aluminum billet, Renshape and Urethane.• Urethane cast tooling from masters.• Composite tooling using epoxy and fiberglass.• Pressure boxes, Plug assists, Snap-back boxes• Automated machinery for Blister forming, Product fill, and card sealing.• Card seal dies and chases.• Fixtures and steel rule dies for post form trimming.• Router fixtures both hand router and CNC.• Assembly and glue fixtures.• Design of flippers and pneumatic systems for undercuts.

CNC Machine experience

• HAAS VF-2 VMC CNC machining center• HAAS TL-2 CNC tool room lathe• Milltronics VMD30 100x30x24” Vertical machining center. Cent5 Fanuc G-Code• Millport VMC1000 20x40x20” Vertical Machining center. Mitsubishi Meldas 320M

Fanuc G-Code • Thermwood 5-axis CNC router Fanuc G-Code• Tormach PCNC 4 axis vertical machining center Fanuc G-Code• Milltronics CNC Lathe Cent5 Fanuc G-Code• Tormach PCNC Lathe Fanuc G-Code• Shopbot 3 axis router Fanuc G-Code• Bridgeport CNC retrofit Fanuc G-Code manual coding.

Specialty experience.

Renishaw RenScan 200 Machine mounted digitizing and CMM system +/- .001 tolerance digitizing and reverse engineering.

Imageware Surfacer and TraceCut software for reverse engineering and analysis.

25+ years of experience has generated a long list of accomplishments.

• GE Aerospace - GE90 engine mock ups and airflow test models. Full size combustion chamber and intake precision models.

• GE Aerospace - Mach-1 air flow fiberglass test tunnel• GE Aerospace - Mockups for fit and finish of complete jet engine and components• GE Aerospace - Test sample preparation for acoustic labs• GE Aerospace - Acoustic lab harmonics flow test tunnel and accompanying equipment• GE Aerospace - Airflow test models and supporting structures• GE Aerospace - Carbon fiber reverse thruster tooling and prototypes.• GE Aerospace - Airframe flow test development and directional exhaust control system models.

• Wright Patterson AFB. - Reverse Engineering of non-US flight components

• Duracell/J&J Packaging - Complete blister packaging lines for AA, AAA• Duracell/J&J Packaging - AA 2 Million unit per day automated packaging machine for 50pack Mil.

Boxes. Using electromagnetic handling technology.• Duracell/J&J Packaging - 25 Automated detrayers for removing AAA and AA batteries from Duracell

bulk packs • Bestop/Dacoma - Jeep Fender flares - Design, Prototype, and Tooling• Bestop/Dacoma - Jeep Center Console - Design, Prototype, and Tooling• Bestop/Dacoma - Jeep Molded Doors - Design, Prototype, and Tooling• Bestop/Dacoma - Jeep Sound Bar - Design, Prototype, and Tooling

• Kenner Products (Now Hasbro) - Blister forming tooling and prototypes for Toys.

• Multi-Form Plastics - In plant material handling pallets vacuum formed and twin sheet formed for Ford and General Motors.

• Northwestern University - lightweight fiberglass body components for solar car research project

• Head case Helmets - Reverse engineer Refine and tool for production of professional hockey helmet

• Bell Helmets - Design, Prototype and tool for bike, football, ski, and watercraft helmets

• Adams - Design, prototype and tool for high school football helmets

• Lexington Safety - Design, prototype, and tooling for equestrian, fire and safety helmets

• Crown Forklift - Reverse engineering and tooling for Crown forklift plastic molded parts.

• Advanced Drainage Systems - Tooling for irrigation pipe ranging from 4" to 36" pipe.

• Sunrise Medical - Design of fatigue and crash testing lab equipment• Sunrise Medical - Re-design and rebuilding of Lab equipment• Sunrise Medical - Prototype complete electric wheelchairs and scooters.

• SIRC - Design, prototype and tooling for crash test heads for sports helmet impact testing.

• Honda - Digitize, reverse engineer and verify stamping dies for misc. automotive components• Honda - Carpet molds for production and water-jet trimming fixtures

• National Geographic - Development of critter cam software, electronics, and attachment systems.

• Hydro Technologies - Worked with General Atomics on the Magnetic levitation train test system

• Hydro Technologies – Developed magnetic measurement and communications methods for a variety of Military and civilian companies.

• Hydro Technologies - Developed deep sea oil communications electronics and high pressure system measurement devices

GE Aerospace Jet Engine Mockups

I was part of a team responsible for the fit up of the gearboxes and miscellaneous jet engine components. We worked from Blueprints and had to build the patterns for the parts without the aid of computers or CNC’s. After the parts were cast we were responsible for machining them to the midpoint of tolerance for the fit up. All of this work was done manually from traditional Blueprints, as there were no CAD systems in use at General Electric Aerospace yet.

GE-90 Air flow test modelsThe development of the GE-90 engine put us to task making airflow test models.

These models were machined from Aluminum and Mahogany to tight tolerances. The fuel mixing section shown below was used to verify atomization for the fuel in GE’s wind tunnel.

Molds and tooling for plastics. Blow molding tool machined from solid billet.

Magnetic Levitation train control system installed and implemented at General Atomics, San Diego

Deployment of National Geographic Crittercam on a great white shark. I machined the clamping mechanism, deployment pole and worked on the team

that developed the dive profiling software.