Sr. Mechanical Engineer at MG McLaren Engineering Group
Greater New York City Area
- Current
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- Sr. Mechanical Engineer at McLaren Engineering Group
- Past
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- Presented technical paper at Earth and Space Conference
- Senior Mechanical Engineer at Melard
- Senior Mechanical Engineer at PRG
- Senior Mechanical Engineer at Scenic Technologies
- Mechanical Engineer/Designer at Disney's Beauty and the Beast
- Senior Staff Engineer at Loral Fairchild Space Systems
- Project Engineer at Anorad
- Staff Engineer at Grumman Aerospace
- Mechanical Engineer at Aeroflex
- Education
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- New York University
- Washington University in St. Louis
- John F Kennedy High School
- Recommended
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4 people have recommended Stephen - Connections
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93
connections
- Industry
- Entertainment
- Websites
Stephen Sywak’s Summary
Professional Engineer in New York and Nevada (Mechanical Engineering)
Besides the purely professional goal of getting better and better at the work I do, and working on more exciting and challenging projects, I also harbor the personal goal of becoming the Technical Consultant for the science fiction film "Ender's Game," based on the book of the same title by Orson Scott Card. (And, just in case my boss is looking, let me be specific: while maintaining my position as Senior Mechanical Engineer at McLaren Engineering Group!)
I'm about three-quarters of the way there...no, make that 4/5ths. My designs for the Battle School are now being used by Marvel Comics (with my permission and under contract) in their new "Ender's Game" comic. And we all know what Marvel does with good Comics properties...
Stephen Sywak’s Specialties:
Integration, Automation, Robotics, Force-Compliant Servo Control, Mechanical Engineering and Machine Design, Structural design and analysis, Marine equipment, Film and Theatrical Effects, Concept Development, Thematic Consulting
Stephen Sywak’s Experience
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Sr. Mechanical Engineer
McLaren Engineering Group
(Privately Held; 51-200 employees; Entertainment industry)
February 2001 — Present (8 years 6 months)
Senior Mechanical Engineer with the McLaren Engineering Group Entertainent Division.
McLaren is a multi-disciplinary consulting firm. Departments include civil, structural, marine, forensics, and entertainment engineering. The Entertainment Division has many years of experience with theater, film, "ride and show," and related entertainment venues.
My background includes military/aerospace, robotics, industrial processes, and design-for-manufacture of consumer/pro electronics, but more specifically at McLaren it includes the design and analysis of large and moderate scale direct and servo-controlled effects, and static and dynamic structures. Two of my more recent projects include the 6-DOF robotic arm used to fly the car from the Broadway production of Chitty-Chitty-Bang-Bang out over the audience, and the two large performance-platform effects ("Gantry Lift" and "Tatami") from Cirque du Soleil's new Las Vegas specatacular, "KA" (www.ka.com) at the MGM Grand Casino/Hotel. -
Presented technical paper
Earth and Space Conference
(Educational Institution; 201-500 employees; Aviation & Aerospace industry)
March 2004 — March 2004 (1 month)
"A Novel Approach to Intra-Station Transfers between Large Centripetal Habitation Wheels and Stationary Utility Cores"
http://scitation.aip.org/getabs/servlet/GetabsServlet?prog=normal&id=ASCECP000153040722000137000001&idtype=cvips&gifs=yes -
Senior Mechanical Engineer
Melard
(Privately Held; 51-200 employees; Computer Hardware industry)
November 1999 — February 2001 (1 year 4 months)
Led the mechanical engineering design team in the update of the company's flagship product: "Scout", a MIL-STD-810 rugged, wireless laptop computer aimed at the telecommunications industry. Designed the company's first docking station for the Scout, leading to over $500K in initial unit sales upon release.
Company has since been purchased by "Microslate." -
Senior Mechanical Engineer
PRG
(Privately Held; 51-200 employees; Entertainment industry)
1992 — 1999 (7 years)
* Project Engineer, Universal Studios’ “Terminator 2 in 3D” (Orlando & Hollywood) and other concurrent projects
* Designed & analyzed servomechanisms and structures for theatre, theme park, film & corporate/industrial productions: Beauty and the Beast (NY, Japan, Mexico, US Tour), Miss Saigon (US Tour), RIO Sky Parade (Las Vegas), Disney/ABC Studios (NYC), Daimler-Chrysler, IBM, Pfizer, MGM/EFX, others.
* Designed/implemented servo-effects with fractional to 50 Hp electric and hydraulic motors, DC and AC (brushless) servomotors, stepper motors, vector-drive motors, pneumatic and hydraulic actuators, ballscrews, timing belts, gears, gearboxes, chain drives, cams, friction wheels, cable drives, plus specialty components such as Serapid push-chain, and Spiralift assemblies.
* 2D & 3D design, FEA, PLC programming, data acq., troubleshooting and prototype testing.
* Designed in wood, steel, aluminum, acrylic, artistic treatments, and other materials as required. -
Senior Mechanical Engineer
Scenic Technologies
(Entertainment industry)
1992 — 1999 (7 years)
(See PRG description)
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Mechanical Engineer/Designer
Disney's Beauty and the Beast
(Entertainment industry)
1992 — 1994 (2 years)
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Senior Staff Engineer
Loral Fairchild Space Systems
(Public Company; 501-1000 employees; Defense & Space industry)
1990 — 1992 (2 years)
• Developed servomechanisms for pan/tilt control of an integrated video camera system for the space station.
• Selected components and materials based on extreme thermal cycles and outgassing requirements.
• Used computer solid modeling for equipment design and creation of photorealistic presentation graphics.
• FEA used for structural, modal and thermal analysis of pan/tilt unit and specialized video camera.
• Worked with subcontractors to develop fully functional prototypes. -
Project Engineer
Anorad
(Public Company; 51-200 employees; Semiconductors industry)
1989 — 1990 (1 year)
• Directed mechanical, electrical and software engineering/design teams to create high accuracy (10 micron and better) assembly and inspection robots for the electronic circuit fabrication industry.
• Integrated distributed servo control, high-speed vision systems, precision linear and rotary axes, advanced safety interlock systems, and auxiliary process systems on multiple serial ports. Performed electrical integration and programming of third-party process equipment. Updated company’s machine safety systems.
• Developed a force-compliant precision servo-control system. Selected, installed and integrated specialty sensors for assembly robot. Designed spherical air bearing system for precise component alignment.
• Designed and assembled prototype equipment for off-line testing of process methods.
• Prepared and led client presentations, maintained target milestones. -
Staff Engineer
Grumman Aerospace
(Public Company; 501-1000 employees; Defense & Space industry)
1986 — 1989 (3 years)
• Designed servo-actuators and other mechanisms for space-qualified, remotely manipulated, humanoid robots (“Robonaut” project; still active at JSC) and robot-based mobile anti-terrorist devices.
• Designed and analyzed multi-axis, multiple arm robot for ground-based simulation of satellite capture.
• Performed preliminary through production design and integration of equipment with test facilities.
• Directed design reviews at NASA/Huntsville. Produced video presentations for NASA and technical conferences.
• Repaired tendon actuated telerobotic arms. Installed “Stereo-Graphics” 3D video system. -
Mechanical Engineer
Aeroflex
(Public Company; 51-200 employees; Defense & Space industry)
1983 — 1986 (3 years)
• Performed detail design, static and dynamic structural analysis, thermal analysis (including FEA), and configuration studies on gyro-referenced, stabilized tracking systems for Navy, Air Force and other contracts.
• Conducted vibration analysis and testing to military specifications. Designed test fixtures. Set-up, modified, and ran third-party test equipment on-site. Conducted optical and mechanical acceptance tests.
• Negotiated price and delivery of Mil/Aero equipment and components. Established first PCs at company.
Stephen Sywak’s Education
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New York University
Certificate in Film making , Film Making (the old fashioned way!) , 1985 — 1986
Courses in production, filming and editing. Was selected to work (electrician/grip/gaffer) on independent feature film.
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Washington University in St. Louis
BSME , Machine Design, Servo Control, Film , 1979 — 1983
Current Professional Engineering Certification in New York and Nevada (Mechanical Engineering), presented at the 2004 Earth and Space Conference ("Engineering, Construction, and Operations in Challenging Environments")
- Activities and Societies:
- Pi Tau Sigma (student president), Student ASME treasurer (still an ASME member)
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John F Kennedy High School
Additional Information
Stephen Sywak’s Websites:
Stephen Sywak’s Interests:
Robotics, Automation, Space exploration, Ender's Game, Theatrical and Event mechanical effects, Film and motion picture Special Effects, Science Fiction
Stephen Sywak’s Honors:
Presented at the 2004 Earth and Space Conference. Paper titled "A novel approach to intra-station transfers between large centripetal habitation wheels and stationary utility cores" regarding practical aspects of living in an artificial gravity environment in large, long-duration space facilities.
Stephen Sywak’s Contact Settings
Interested In:
- career opportunities
- consulting offers
- new ventures
- job inquiries
- expertise requests
- business deals
- reference requests
- getting back in touch
