Dani Hale

Senior Materials Engineer II

Education

Michigan State University

B.S. / 2012

Experience

ClearMotion

Senior Materials Engineer II / July, 2017July, 2025

Performed all internal materials analyses including metallographic preparation microstructure interpretation hardness measurements wear analysis cleanliness evaluation and fracture analysis. Main point of contact for all materials related requests including general materials analysis fracture analysis wear analysis supplier qualification and design engineering support. Prioritized materials lab related tasks with key stakeholders within the company including high level management and project managers to align with company goals. Supported design and product validation testing by performing wear analysis of individual components failure analysis of any failed components and created technical reports for the customer on all findings. Created a wear database to determine typical observations of each component within the ClearMotion system and used this database to demonstrate any abnormal findings during product validation testing. Applied 8D problem solving methodology to assess investigate and correct complex problems. Developed managed materials test plans for key components to accelerate product learning with minimal resources. Collaborated with local and international cross-functional teams to provide material heat treatment coating and process selection guidance and recommendations for design engineering. Created and maintained a Jira Kanban board to organize the ClearMotion Materials Lab responsibilities to ensure timely completion of tasks. Organized equipment calibrations equipment purchases safety precautions procedures within the materials lab and advised on budget planning. Developed work instructions for the materials lab equipment and materials analyses and used these to train cross functional teams. Maintained and improved all internal materials and surface treatment specifications along with updating the materials library used in SolidWorks. Supported manufacturing process improvement through materials analysis mechanical testing and iterative feedback with suppliers to improve the component(s) performance. Basic knowledge of GDT and working experience with CMMs including Zeiss and Hexagon CMMs. Reviewed and approved supplier documentations such as materials certifications visual inspections and mechanical testing results.

Altran

Materials Scientist / February, 2016July, 2017

Provided technical assistance on a wide range of projects and assignments in a laboratory environment. Created materials testing plans based on the material heat treatment and component environment for a range of components. Conducted failure analyses and material evaluations for various industries such as nuclear biomedical and commercial. Created technical reports for clients and provided improvement recommendations.

Aisin Technical Center of America

Project Engineer / May, 2012January, 2016

Performed materials analysis failure analysis and analyzed material defects to assist design engineers with root cause analysis. Performed microstructure evaluation hardness testing FTIR analysis DSC analysis and SEMEDS analysis. Determined future development projects and best practice by performing benchmarking activities. Created technical reports and presentations of material investigations for company-wide distribution.

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