Sanal Kamal
Cambridge,Canada
Summary
Dynamic Sr Consultant with expertise in semiconductor/Optics and Client relations. Spearheaded the development of advanced camera systems for space applications, ensuring compliance with rigorous standards. Proven ability to lead cross-functional teams and deliver innovative solutions, enhancing product reliability and manufacturability in high-stakes environments.
Overview
11
11
years of professional experience
Work History
Sr. Electro-Optics Consultant
MDA
02.2024 - Current
- Designed replacement camera systems for the ISS and ARTEMIS space station
- Defined optical system specifications for Canadarm3 vision systems and target designs
- Co-developed semiconductor chips and FPGA for camera sensor systems
- Conducted stress and motorization ratio calculations to validate Sarrus linkage system design.
- Developed auxiliary service interface for Canadarm-3 Robotics within NASA's ARTEMIS-2 project.
- Reviewed design reports and analyses to ensure compliance with TRL level for PDR with CSA.
- Prepared comprehensive bonding and grounding layout for Canadarm 3 interfacing architecture.
- Executed design and analysis of on-orbit fueling system.
- Performed design review and verification of engineering work completed by team members.
Photonics Packaging Consultant
Jabil
07.2023 - 01.2024
- Consulted on photonic package development to enhance manufacturability and reliability
- Planned and executed critical development projects for Nokia products with global teams.
- Designed detailed factory layout for semiconductor manufacturing laboratory in Ottawa Canada
- Defined station, test rack, and chamber layouts per CSA-C22.2 and CCPIA standards
- Led cross-functional teams, ensuring effective communication with designers and suppliers.
- Negotiated resource scope and commitments among multiple functional groups.
- Consulted offshore (Malaysia, Shenzhen) semiconductor fab line to improve metrology and inspection
- Plan, initiate, resource and execute critical development projects on schedule for Nokia products with multi-disciplinary global teams from product ideation through to new product introduction
- Modeled subsystems and collaborated with the electrical and civil contractors to execute the build
- Lead, motivated and communicated effectively with designers, executives, suppliers, and customers from around the globe
- Negotiated scope and commitment of resources with several functional groups
- Evaluation of foundries, PDK’s, vendors for capabilities and system compatibility
- Developed and managed program schedules, budgets and resource planning for NPI clients
Optomechanical Engineer, Lead
Honeywell Space
02.2020 - 06.2023
- Led bid and proposal activities for strategic initiatives in space industry.
- Collaborated with customers, marketing, and sales to create business cases for new products.
- Interfaced with R&D, Product Marketing, Manufacturing, Finance, and Sales teams.
- Ensured swift and efficient product development processes across departments.
- Championed product verification, validation, and deployment for initial success.
- Engaged key stakeholders and customers (CSA, ESA, JAXA) to secure product acceptance.
- Designed optical packaging for thermal vacuum, vibration, and shock testing of assemblies.
- Developed mass properties measurement fixtures considering center of gravity of satellite equipment.
- Successfully presented TRR/MRR to customers (CSA, JAXA) and executed tests meeting deadlines
- Performed effective project risk management, to overcome development hurdles
- Co-chaired company’s project meetings to ensure all department leaders meet design specifications, schedules and project budgets
MANUFACTURING ENGINEER, NPI (6m Contract)
L3Harris Corporation
08.2019 - 01.2020
- Led process development for NPI MX series cameras and collaborated with design for manufacturing.
- Supported and enhanced product development and project management processes.
- Ensured all project contract deliverables met verification checklist requirements prior to pre-shipment.
- Developed MAPS, managed non-conformance reports, and conducted root cause analysis on electro-optic assemblies.
- Contributed to operating plans and product roadmaps to align with strategic goals.
- Served as subject matter expert in Zygo optical metrology measurements for lens integrity testing.
- Implemented continuous improvement initiatives in NPI production cycle using lean principles.
OPTO-MECHANICAL DESIGNER
Google - exNorth
01.2018 - 08.2019
- Created test plans and DOE's (Design of experiments) for adhesive shear strength and chemical tests
- Recorded all Research & Development work per project is reported for SR&ED claims
- Audit, analyze and conduct DFM meetings with contract manufacturers to improve process capability
- Designed processes for microelectronic projector manufacturing involving micro-prism (quad prism) integration
- Captured the processes and visualized in JMP for statistical process improvements
- Created product documentation including design specifications, custom part drawings, assembly drawings, BOM’s, technical docs for calibration, training and installation of the whole sizing rig
- Deployed the fabricated design in international retail locations by off-shore travels
PROCESS ENGINEER
Sanmina
06.2015 - 12.2017
- Designed and developed efficient product cycles for mass production of MEMS spectrometers and 5G line cards using lean six sigma methods.
- Created mechanical fixtures and layouts in AutoCAD for machine shop and 3D printing applications.
- Provided RMA process support and conducted analysis on components and circuit boards.
- Facilitated communication among design team, operations, and management to align project goals.
- Monitored SMT lines to assess PCB yields and analyzed failures linked to gerbers.
- Developed optical processes for NPI manufacturing, including custom alignment equipment.
- Executed DFM, FEA, FMEA, Poka Yoke, Six Sigma, and Lean methodologies to enhance production efficiency.
RESEARCH ASSISTANT at Advanced Research Complex (ARC)
University of Ottawa
12.2013 - 01.2015
- Researched proposals for reconfigurable metamaterials utilizing III-V semiconductors.
- Determined photonics applications aligning with product objectives and features.
- Documented design processes for semiconductors using metamaterials and conducted conferences to stay updated on advancements.
- Operated various software tools to execute optical design tasks.
- Utilized lab testing equipment and measurement techniques for fiber optic waveguides.
- Applied knowledge of communication protocols, including TCP/IP, OTN, Ethernet, SONET, and Fiber Channel.
Education
MASTER OF ENGINEERING - Optical, Electronics, Management
UNIVERSITY OF OTTAWA
01.2015
BACHELOR OF ENGINEERING - Electrical & Electronics, Software, Management
UNIVERSITY OF KERALA
01.2012
Skills
- Semiconductor design
- MATLAB programming
- 3D modeling with AutoCAD
- Creo and SolidWorks expertise
- NX software proficiency
- Project management with Microsoft Project
Summary Of Qualification
- Proficiency in Optical Metrology and expert in tools like Creo, Solidworks, NX
- P.Eng and PMP Certified
- Product development and Product Lifecycle Management from cradle to grave
- Experience in New Product Introduction (NPI) and experience in using Statistical Process Control (SPC), control charts and cpk analysis
Timeline
Sr. Electro-Optics Consultant
MDA
02.2024 - Current
Photonics Packaging Consultant
Jabil
07.2023 - 01.2024
Optomechanical Engineer, Lead
Honeywell Space
02.2020 - 06.2023
MANUFACTURING ENGINEER, NPI (6m Contract)
L3Harris Corporation
08.2019 - 01.2020
OPTO-MECHANICAL DESIGNER
Google - exNorth
01.2018 - 08.2019
PROCESS ENGINEER
Sanmina
06.2015 - 12.2017
RESEARCH ASSISTANT at Advanced Research Complex (ARC)
University of Ottawa
12.2013 - 01.2015
MASTER OF ENGINEERING - Optical, Electronics, Management
UNIVERSITY OF OTTAWA
BACHELOR OF ENGINEERING - Electrical & Electronics, Software, Management
UNIVERSITY OF KERALA
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