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CV

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Summary

Materials scientist and process development engineer with over a decade of building manufacturing processes and equipment from scratch. My work spans chemical reactors, automated control systems, electronic interfaces, DAQ backplanes, and mechanical testing equipment. My process centers on identifying the critical needs of a project, working out potential solutions for each, and iteratively combining them to maximize the safety, reliability, ergonomics, and scalability of the end result. I have led cross-functional projects and delivered on schedule under live production conditions. My PhD is in Applied Physics and Materials Science, I hold two US patents, and I have authored several peer-reviewed publications.

Core Competencies

Process Development
Process characterization, DOE, reactor scale-up · Critical process parameter identification and control · Equipment and tooling design · Process qualification and validation planning

Engineering & Fabrication
Mechanical design (SolidWorks, AutoCAD) · Advanced manufacturing (DMLS, CNC, FDM, welding, sheet metal) · Instrumentation and automation (LabVIEW, Python, MATLAB, ESP-32) · PCB design · Vacuum system design · Smart materials / SMA (Nitinol)

Analysis & Problem-Solving
Failure mode analysis and risk-based thinking · Statistical analysis and data-based decision making · Materials characterization (TEM, SEM, CBED/STEM, EDS)

Leadership & Communication
Cross-functional project management · Technical documentation and communication of advanced concepts to varied audiences · Fluent in Spanish

Experience

Cornerstone Building Brands

Sr. Structural Lab Engineer | 11/2025 – Present

  • Rescued a multi-million dollar project where panel span requirements had exceeded available product performance ratings: proposed a novel experimental clip paired with an existing system, coordinated testing in just over a week (vs. the standard 1–2 months), and raised allowable uplift pressure from 81 to 121 PSF
  • When the same customer returned requiring 136 PSF on one building, identified the failure mode as clamp performance, swapped to an improved clamp, retested, and achieved 153.84 PSF — nearly double the system's original rated capacity
  • Designed and built a test chamber to AISI-S908 standards with Python-based data acquisition integrating pressure sensors, wire draw encoders (0.1mm resolution / 1000mm range), temperature and humidity sensors, POE IP cameras, and VFD-controlled pressure regulation
  • Built a custom automated data logger for in-house pull testing using a modified crane scale that enabled a button-triggered CSV export of the last 30 seconds of data at 80 S/s prior to part failure; this included a self-hosted web interface for calibration, visualization, and log retrieval
  • Managing Florida, Miami-Dade, TDI, and Factory Mutual product approvals; building a testing records and BOM database to centralize approval management and enable dynamic updates to customer-facing materials

Champion Fiberglass

R&D Technical Lead | 05/2024 – 06/2025

  • Designed and built a 10,000 PSI hydrostatic pressure test rig in two weeks; the system ran its first validation jobs within days and secured a major geothermal tubing client
  • Engineered a cable friction tester with integrated multi-axis load sensing to characterize the friction coefficient of cable-conduit material combinations
  • Designed a 40,000 lb adhesive joint pull tester for in-house validation of bonded FRP assemblies
  • Developed a collapsible mold system for filament-wound FRP elbows; reusable and technician-serviceable, it opened a product line that wasn't previously feasible
  • Led a $6M facility expansion, compressing timeline from 8 to 4 months and saving $3.8M in opportunity costs through process redesign, regulatory problem-solving, and aggressive critical path management
  • Coordinated 60+ people including architects, civil engineers, electricians, automation contractors, and government agencies without interruptions to ongoing plant operations during expansion
  • Resolved regulatory setbacks within 30 days through rapid re-engineering: repurposed inventory, relocated equipment and processes, and deployed portable chemical storage and utility systems

Northern Arizona University – APMS

Research Assistant | 05/2021 – 05/2024

  • Planned and executed systematic characterization studies of carbyne and quasicrystal nanomaterials using CBED/STEM workflows designed to maximize data quality while minimizing beam-induced sample damage
  • Derived a novel mathematical formula enabling HOLZ-ring structural analysis at off-axis orientations in quasicrystals, extending characterization capability beyond existing literature methods
  • Converted an under-equipped lab into a functional TEM facility in 3 weeks, coordinating HVAC redirection, electrical rewiring, chilled-water replumbing, and window removal; achieved 0.93 Å resolution versus the manufacturer-specified 1.0 Å through acoustic isolation, controlled HVAC, and stable power
  • Built a research instrumentation workshop including machining tools, DAQ systems, 3D printers, and an electronics test bench, and used these to mentor graduate students in process and system design while demonstrating drafting and fabrication techniques
  • Sourced a used Fischione 1020 plasma cleaner for ~$5K, diagnosed and fixed it for under $1K in parts, effectively bringing a $50K+ instrument into service while saving $44K
  • Designed and built a Nitinol SMA wire actuator with closed-loop PID force control using a PZT piezoelectric force sensor; characterized the wire's austenite start temperature, austenite stress influence coefficient, and heat transfer coefficient experimentally when manufacturer specifications were unavailable, then validated a full thermal-mechanical model against measured performance (ME475/575 Adaptive Materials and Systems, course project)

Ambercycle

Senior Engineer | 08/2018 – 12/2020

  • Designed and commissioned three pilot-scale reactor systems for polymer solvent-extraction recycling: process and equipment specifications, hazard analysis, critical parameter identification, and qualification testing
  • Engineered a 600 psi / 400°F pilot reactor processing 100 kg batches of PET and chlorinated solvents with zero acceptable operator exposure: designed containment enclosure, full remote valve automation, nitrogen-pressurized gate valve seals, and SCBA safety protocols
  • Performed systematic materials compatibility analysis to select mild steel over stainless steel for reactor construction based on chloride-induced IGSCC risks; this choice was later validated when stainless components elsewhere showed early-stage corrosion while mild steel components remained unaffected
  • Characterized and optimized a solvent condensation system: identified root cause of seasonal throughput failure (ambient temperature at phase separation), redesigned with vacuum-assisted condensation and achieved improved output with less fouling and degradation
  • Designed and iterated a jet crystallization nozzle through geometry optimization, which eliminated clogging entirely; system completed hundreds of batches without a single failure after implementation
  • Engineered an automated liquid-gas interface condenser / phase separator for solvent recovery; achieved approximately 83% reduction in solvent losses through performance characterization and design refinement
  • Built modular logic automation systems and 12-channel PID control enclosures for remote chemical process control within a sealed hazardous-material containment room
  • Directed build-out of lab, machine shop, and process space from shell; specified compressed-air distribution, fume hood systems, and ventilation in compliance with local code and safety requirements

Intel (via Oxford Global Resources)

Design Engineer / Metrology Expert | 06/2017 – 08/2018

  • Redesigned legacy DAQ systems with modular connector-based architecture and precision PCB-integrated shunts, reducing annual calibration downtime from days to hours and initial assembly time by 90%; design was subsequently standardized across the entire Chandler Thermal Lab
  • Developed LabVIEW software for automated process control, per-unit data logging, and traceability across thermal interface material testing workflows
  • Engineered a precision automated chip attachment system replicating production packaging conditions: ±0.2 lb force accuracy, ±3°C thermal stability, vacuum-actuated part placement, and solenoid-controlled sequencing
  • Designed microchannel liquid cooling manifolds for high-performance processors using iterative 3D-printed prototyping and CNC-machined final parts

Centrix Engineering

Failure Analysis Engineer | 03/2017 – 06/2017

  • Investigated failure modes in plumbing systems through optical microscopy, hydrostatic pressure testing, and targeted disassembly; identified root causes including corrosion, weld defects, and stress concentrations
  • Diagnosed a self-sealed weld pinhole in a water heater by detecting external mineral residue deposits, performing targeted disassembly, and confirming failure mechanism through direct inspection and microscopy

Arizona State University – Engineering School

Research Assistant | 06/2016 – 05/2017

  • Characterized creep behavior in DMLS vs. wrought Inconel 718 through tensile testing, SEM, and TEM; identified the microstructural reasons DMLS samples consistently outlasted wrought under the same conditions

Implementing Ideas

Administrator | 05/2016 – 08/2016

  • Coordinated procurement and logistics for PCB assembly projects
  • Digitized all production documentation and deployed a secure tablet-accessible server, improving workflow and traceability

ASU & Intel

Equipment Engineer | 11/2014 – 06/2015

  • Developed a non-destructive electromigration test system capable of screening junctions in real time; this was a significant improvement on the standard approach, which relies on destructive testing; system and methodology awarded US Patent US10468331B2

Van Dellen Steel West

Drafter / Detailer | 06/2015 – 01/2016

  • Created fabrication-ready steel drawings using SDS/2 and ProNest, optimizing material use
  • Designed retrofit cooler hangers and spring-loaded parking signs to resolve persistent safety and integration issues

Zero Mass Labs

Solar System Engineer / Fabricator | 08/2014 – 12/2014

  • Redesigned solar thermal panel assembly methods and introduced sheet metal fabrication to replace machining steps, reducing lead time and production cost by 50%

Arizona State University – Department of Chemistry

Laboratory Research Assistant | 05/2010 – 08/2014

  • Built custom deposition tools and seal systems for corrosive environments
  • Installed lab infrastructure, developed waste systems, and authored control/data software for repeatable experimentation

Education

PhD, Applied Physics & Materials Science
Northern Arizona University, 2024
Dissertation: TEM Strain Analysis of Multimetallic Nanomaterials

MS, Engineering
Arizona State University, 2017
Thesis: Strain in DMLS Inconel Microstructure

BSE, Materials Science
Arizona State University, 2012

Patents

  • US10468331B2 — Heat Management System (Intel Corp, 2018)
  • US10043720B2 — Interconnect Simulation & Characterization (ASU, 2016)

Publications

  • Rogers, B. et al. Decahedral Multimetallic Nanoparticles via CBED. PCCP, 2025
  • Rogers, B. Creep and Microstructure in DMLS vs. Wrought Inconel 718. TMS Annual Meeting, 2018 (Conference Presentation)
  • Rogers, B. Structure and Strain Analysis… ProQuest, 2025 (PhD Dissertation)
  • Rogers, B. et al. Anomalous Crystallization of Au and Other Metals. Crystal Research and Technology, 2023
  • Velázquez Salazar, J.J., Rogers, B., et al. Pseudo Carbynes via Gold-Thiol Stabilization. Carbon, 2024
  • Castañeda, J., Rogers, B., et al. Nanoclusters for Microswimmer Motility. Small, 2025