Carol’s biggest career challenge came during her second contract with the client, when she was appointed to lead the strength effort to optimize Vulcan Boost and Upper Stage parts redesigned using additive manufacturing (AM).

• The required safety factors for AM parts were significantly higher than those for traditional wrought materials.
• A steep knockdown factor was applied to fatigue life curves to account for a lower endurance limit.
• Each part went through multiple rounds of design and analysis.

Of roughly 22 components considered, only four were successfully redesigned. Twelve others cleared rigorous design iterations but were ultimately shelved due to weld safety concerns, underscoring how demanding the effort was.

“Despite the less-than-stellar outcome, it was exciting to help bring four designs to closure and to lead this strength effort while being involved at the forefront of advancement in manufactured technology.”

Before this engagement, Carol analyzed jet engine assembly and disassembly tooling, working with relatively simple, limited load cases. Rocket hardware demanded a different level of rigor entirely, including:

• Vibratory loading across all orthogonal directions.
• Coupled Loads Analysis output from the client’s Structural Dynamics group.
• Enforced displacements and thermal loading.

Her work certifying the Interim Cryogenic Propulsion System (ICPS) for human flight on NASA’s Artemis missions pushed her fracture mechanics expertise even further. Close collaboration with Avionics, Design, Thermal, and Structural Dynamics teams became central to her growth as a strength analyst.

One of Carol’s proudest moments came when she picked up an analysis left behind by a departing colleague, with little handoff documentation. Her task was to redesign a mounting provision tower bracket on the Centaur V Aft Bulkhead to carry additional harness wires.

A load audit uncovered a critical issue: the original design was modeled incorrectly, resulting in inaccurate safety margins. Working against production deadlines, Carol iterated on tower thickness, fillet radii, and slot placement to strengthen the design while minimizing added mass. The analysis required both linear and non-linear methods to satisfy weld margins.

She delivered on time and on budget. The resulting design now supports the remainder of the Vulcan fleet.

Carol keeps her skills sharp through a mix of formal training and self-directed learning:

• Follows aerospace industry news via LinkedIn
• Completed FEMAP courses for finite element pre- and post-processing
• Learned Altair HyperWorks on the job
• Uses online how-to resources, including FEMAP manuals compiled by ATA Engineering

Carol’s top piece of advice is to ask for help. Her team used group chats to crowdsource tough questions, and while it wasn’t always comfortable, the time saved was immediate. She also encourages professionals to volunteer as peer reviewers as often as possible, calling it one of the fastest ways to build skills on both sides of the review process.

In Carol’s view, the best PDS consultants share a few key traits:

• Self-motivated and willing to learn from mistakes
• Ready to take on challenges outside their comfort zone
• Clear communicators who collaborate well across teams
• Willing to put in extra effort when milestones demand it
• Backed by a strong, honest work ethic

Networking has directly shaped Carol’s career path, helping her move from one contract into a second with the same client. She’s stayed connected with former colleagues, including a mentor, who may play a role in her next opportunity. She’s also paid it forward, mentoring a newer analyst through the fundamentals of the job.