I am a forging and design engineer in Boston, Massachusetts specializing in forging processes for the automotive, medical, and aerospace sectors. My career has been built on a foundation of solving complex design and manufacturing challenges, from large-scale entertainment structures to high performance automotive engine and industrial components.

I focus on optimizing processes from start to finish. My expertise lies in die design, process simulation (DEFORM, FEA), and hands-on improvement for near-net shape forgings in high-performance alloys. I bridge the gap between design theory and shop-floor reality, ensuring components are manufactured efficiently and to the most exacting quality standards.

My core skills include:

  • Hot Forging Process Optimization/Simulation & Die Design

  • CAD System Management & Automation (Creo, SolidWorks, Inventor, AutoCAD)

  • Root Cause Analysis, Cost Reduction, Continuous Process Improvement

  • Design for Manufacturing (DFM) and Iterative Innovation

    Forge Engineering Articles: Forge Optimization

    LinkedIn: www.linkedin.com/in/isaaccogdill

A happy family of three, including a woman, a man, and a small child, standing on a rocky coastal pathway with the ocean in the background.

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Experience

Tecomet, Inc

AME - Principal Engineer (Forging)

March 2025 - Present

Boston, MA

  • Collaborate with all forging sites to identify, develop, and support forge process improvements, die design and simulation, engineering change implementation, and root cause analysis activities.

  • Develop forge processes on new medical device and aerospace programs and projects to ensure successful launch and manufacturing efficiency.

  • Provide forge process insight and solutions as part of the interdepartmental Advanced Manufacturing Engineering team.

  • Deliver forge process insight and solutions to all forging operations to support cost reduction efforts and improve manufacturing/metallurgical repeatability with support readily available remotely and on-site.

Stagecraft Industries, Inc.

Computer Aided Design System Manager

March 2023 - March 2025 (2 years 1 month)

Portland, OR

  • Ensured design team workflow ran smoothly via direct support and building/automating multiple standard CAD processes.

  • Created and managed design tools, such as templates, AutoLISP routines for design rule streamlining, part libraries, and efficiency improvements.

  • Minimized design markups and revisions by standardizing design rules and components.

  • Managed CAD software updates, settings, and technical issues.

Federal-Mogul Powertrain (Global Valvetrain)

Manufacturing Engineer (Forging/Deep Drilling/Friction Welding)

June 2016 - March 2023 (6 years 10 months)

Sevierville, TN

  • Designed, developed, and implemented hot forging process improvements for near-net shape forgings with minimal flash used in engine valve production.

  • Experienced with forging and hot/cold heading various stainless steel alloys containing high amounts of chrome, silicon, and nickel, including both martensitic and austenitic steels.

  • Led manufacturing engineering duties on pre-forging processes from shearing, drawing, extruding, upsetting, and hot forging, including post-forging operations.

  • Transitioned new products and processes from initial design in PTC Creo, through simulation in DEFORM, to full production via PPAP.

  • Captured numerous cost reductions related to die design, lubrication delivery, part handling, and machine loading/unloading.

  • Solved quality problems through FMEA and designed process control improvements.

  • Involved in every step of continual process improvement within design, analysis, measurement, testing, and prototype manufacturing.

  • Collaborated with internal teams, customer engineers, and external labs to develop and optimize heat treatment parameters.

  • Invited to be part of Toyota's Monozukuri global multi-supplier process improvement team.

  • Excellent at ensuring buy-in on process changes with operations teams and building confidence from the shop floor to the customers.

James Thomas Engineering / TOMCAT USA

Design Engineer

December 2012 - June 2016 (3 years 7 months)

Knoxville, TN

  • Designed structural touring rigs for efficiency in materials, manufacturing, and transportation.

  • Solved problems with shop methods and improved in-house workflows.

  • Designed new jigs and machine tools to enhance productivity.

  • Tested and analyzed models with SolidWorks, COSMOS, and AutoDesk Multiphysics.

  • Developed structures from concept through 3D models and into shop drawings, including all relevant GD&T and machine notes.

  • Designed concert structures for major artists, support structures for NASA JPL, and various other installations and product designs.

ITT Technical Institute

Adjunct Instructor

December 2012 - May 2013 (6 months)

Knoxville, TN

  • Classroom and Lab Instructor for "3D Parametric Modeling" and "Materials and Manufacturing Processes".

  • Taught skills utilized in computer-aided drafting, design, and manufacturing engineer positions.

  • Instructed students in Parametric Modeling using Autodesk Inventor, conventional drafting methods, GD&T, and file organization.

Education

Middle Tennessee State University

  • Bachelor of Science (B.S.), Aerospace Science [Engineering Design] (2006-2010)