Bjorn Rudgley

Experience

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  Hawker de Havilland - Boeing Aerostructures

  Jan 1997 - Jan 2008

  Production Team Lead

  Manufacturing of advanced composite and metallic aerostructures for Boeing, Airbus, Bombardier, Lockheed, McDonnell Douglas, BAE, Ratheon, Royal Australian Navy (RAN).During my time at Hawker de Havilland / Boeing Aerostructures, I rotated through all production areas, the majority of my time in composite laminating or assembly departments. Ultimately selected for the roll of production lead for Bombardier's Challenger 300 composite tailcone program. Responsibilities included:- Production of autoclave cured composite parts and tooling and tooling aids.- Production of composite and metallic assemblies and sub-assemblies in controlled fixtures.- Repairs to composite laminates.- Standardising production processes, tooling, material and LEAN improvements.- Training and mentor for trade and apprentice staff in production techniques.- Area fire safety warden and OH&S committee member.Key Accomplishments:- Developed composite co-cured stiffener tooling and production methods with prepreg carbon.- Created composite in and out of autoclave diaphragm moulding technologies with prepregs.- Recognised for significant reductions in cycle time for production of the Challenger 300 composites program through development of innovative production aids, manufacturing techniques, and implementing LEAN principles - D.Carbon G.M. 2005. Show less

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  Silvertone Electronics

  Jan 2005 - Jan 2008

  Flamingo UAV Airframe Production Engineer

  I was chosen to assist with the development of a high speed 4 meter span UAV with up to 7 hours endurance. Silvertone Electronics had previously pioneered RC piloted drones in the early 70's. This aircraft would take advantage of modern composite technologies and aerodynamic design.Responsibilities included:- Design and construction of all prototype tooling using mostly traditional pattern making skills.- Structural component design.- Construction and assembly of prototype and initial production run of composite airframes.- Carried out payload design, autopilot integration and flight testing.- Created production drawings and templates as required for initial production.- Assisted the primary designer (J.Haren) with several aerodynamic elements which contribute to the overall design success.Participated in the first UAV outback challenge at Kingaroy, Australia 2006. Show less

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  Radotec

  Jan 2008 - Jan 2011

  Design Engineer and Factory Manager

  Radotec was tasked with the ambitious 2 year design and fabrication of BioPower Systems $10 million bioWave, bioStream and O-Drive ocean energy devices. As factory manager, I assisted our engineering team with the design and assembly of the prototype machines.Bosch Rexroth and Siemens assisted in providing key technical input throughout the process.Radotec latter developed a series of small scale carbon composite wind turbines and proprietary technologies relevant to this industry. Target markets were above urban buildings, along freeways and parklands, and in rural settings. The Radotec turbine is now being produced by Axowind.Key responsibilities:- Factory planning and fit out.- Mechanical and Industrial design (Solidworks/Rhino 3D).- Carbon composite fabrication with vacuum infusion and vac bag or hand lamination and RTM Lite.- CNC Machining of parts for machines and patterns for composite tooling. CNC trimming.- Construction and testing of VAWT wind turbines, UAV airframes, Tidal and Wave Energy TU. - Filming & editing of promotional videos (Radotec VAWT)- Photorealistic Rendering in FlamingoKey accomplishments:- The bioWAVE design selected for Smithsonian Cooper-Hewitt Triennial Exhibition in New York.- Obtained an intellectual patent applicable to wind turbines.- We were awarded a $500K Government funding grant for our wind turbine.- Designed and built and tested a working prototype turbine in 1 year.- Resin infusion of all carbon fibre structural components for the prototype turbine.- Detailed design of production ready composite parts and assemblies. More information to be found at:http://bps.energy/https://www.axowind.com/about-us/ Show less

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  Ryman Composites Pty Ltd

  Jan 2011 - Nov 2022

  Manufacturing Manager

  Ryman Composites specialised in manufacturing ongoing production of high quality composite components for various industry sectors for over 30 years. Parts were produced using RTM, Resin Infusion, Vacuum Bag, Spray-Up and traditional hand lay processes. Formerly known as NoseCone Australia Pty Ltd, Ryman Composites launched Ryman Campers RCRV business in 2021. Offering their own range of HiRoof and Pop-Top Campervans for leisure, rental fleets and service vehicles based on Toyota Hiace and Commuter vans. Show less

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  World Class Composites

  Feb 2022 - now

  Operations Manager

  World Class Composites specialises in creating high quality A1g3 out of mold surface finish composites for a variety of industry sectors. We provide comprehensive conceptual and detailed product and tool design utilising 3D CAD modelling, traditional or CNC assisted pattern and tool / mold fabrication, and batch production by JIT.We are also skilled in reverse engineering design through digital surface scanning.Formerly known as Ryman Composites Pty Ltd, World Class Composites manufactures parts using RTM, Resin Infusion, Vacuum Bag, Spray-Up and traditional hand lay processes. Please visit:https://www.worldclasscomposites.com.au/ Show less