Ali Abu ali

To obtain a mid-level position as a structural design engineer, allowing me to utilize my education while gaining valuable work experience in a team-oriented environment.

Validation Engineer (Sikorsky UH-60A) at NobleTek (2026-03 – Present)

• Created new Model-Based Definition (MBD) from legacy 2D CAD drawings, part list and operation sheets.
• Validated the quality of the converted designs to ensure they match as-built parts.

Structural Design Engineer (Boeing's Strut/Nacelle) at Spirit AeroSystems (2019-04 – 2025-10)

• Developed new engineering CATIA V5 CAD models and modified existing composite and metallic parts and assemblies to optimize Thrust Reverser designs.
• Supported MRB (Material Review Board) activities by analyzing non-conforming parts, identifying root causes, and developing repair, rework, or use-as-is dispositions.
• Created rework instructions and drawings to address Non-Conformance Reports (NCRs) for surplus, damaged, or out-of-tolerance parts and assemblies.
• Generated static, fatigue, and drainage test reports to validate new designs of fluid and aerodynamic seals.
• Generated tolerance analysis and GD&T on assembly stack-ups to ensure no interferences or mismatch between parts on installation.
• Created rework instructions and drawings for surplus parts and assemblies.
• Coordinated with multiple suppliers to improve and control the manufacturing process and ensure new designs are feasible and producible.
• Visited Boeing's sites to inspect and develop rework drawings and instructions.
• Worked on PDR and CDR for new projects.

Bachelor of Science in Mechanical Engineering – Wichita State University (2013-08 – 2018-12)