Emmanuel Galvan

Manufacturing and NPI Engineer with experience in tooling design, fixture development, and process validation across HVAC, automotive, and heavy manufacturing industries. CSWP-certified with strong background in SolidWorks, FEA, and rapid tooling using additive manufacturing. Proven experience designing 50+ fixtures per year and supporting new product introduction from concept to production. Focused on improving manufacturability, reducing scrap, and optimizing production efficiency.

NPI Engineer at American Tubing International (ATI) (2025-04 – Present)

• Designed and developed fixtures, bend formers, punches, and clamping systems for tube bending and brazing processes.
• Evaluated manufacturability of new products and defined tooling requirements for production.
• Reduced setup scrap by implementing 3D-printed bend gauges for first-piece validation.
• Performed load and moment analysis for lifting devices, identifying critical risks and proposing design improvements.
• Collaborated with tool room and production teams to manufacture, validate, and release tooling.
• Supported NPI phases (EVT/DVT/PVT) ensuring smooth ramp-up to mass production.
• Generated and maintained technical documentation to support production and tooling standardization.

Senior Tooling Design Analyst at Trinity Rail (2023-01 – 2025-04)

• Designed and optimized fixtures, templates, and tooling for railcar manufacturing processes.
• Performed pre-analysis for line changes, ensuring tooling readiness for new product configurations.
• Calculated center of gravity and load distribution for lifting and rotation operations.
• Designed lifting devices, structural platforms, and material handling racks with safety factor validation.
• Performed FEA using Autodesk Inventor to validate structural integrity and performance.
• Reduced changeover time from 1–2 days to a few hours through fixture standardization.
• Developed and documented 150+ rack designs improving material handling efficiency.
• Implemented 3D printing for lightweight templates, improving ergonomics and operator efficiency.
• Created simulations and visual presentations to communicate engineering solutions.

Senior Tooling Design Analyst at Trinity Rail (2023-01 – 2025-04)

Key Projects

• Designed a universal fixture for 15+ railcar models, reducing setup time significantly.
• Developed a rotator base system reducing setup time from 12 hours to 1 hour and improving operator safety.
• Implemented a rack catalog system (150+ designs) for faster material selection and logistics optimization.
• Led implementation of 3D printing for tooling and templates in production.

Industrial Designer (Tooling) at EMDEP Testboards (2022-06 – 2023-01)

• Designed 4+ validation modules per day for automotive wiring harness testing.
• Developed systems for continuity, presence, color, leak, and vision-based validation.
• Implemented poka-yoke solutions to prevent assembly errors in similar harness configurations.
• Generated CNC-ready designs and supported CAM programming.
• Integrated pneumatic systems for clamping and detection applications.

Product Engineering Intern at Kandor (2022-02 – 2022-05)

• Designed welding fixtures for grills and smokers manufacturing.
• Developed sheet metal components and laser cutting layouts.
• Performed reverse engineering for U.S.-based clients.