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Glenn DiCostanzo

BIO

Summary:

Seasoned mechanical and metallurgical engineer with project management expertise. Diverse experience ranging from R&D to operations in regulated, medical device industry. Hands on engineering and project leadership. Seeking project work; available to assist manufactures with product development, product improvement, and quality initiative projects.

Work Experience

GD Consulting llc, Principal & Founder, 2017-Present
Engineering and project management services. Including CAD modeling and drafting (SolidWorks); data reporting, visualization, and analysis (python); materials consulting; engineering documentation creation and review; quality consulting and planning; project planning and execution.

Orchid Orthopedics, 2010-2017
Worldwide leader of medical device outsourcing services, providing expertise in design and development through finished goods manufacturing.

Production Manager, Jan 2015 – 2017

  • Managed team of 50 personnel across 3 shifts. Responsible for ensuring safety of shop personnel, quality and delivery of product, and driving strategic LEAN initiatives.
  • Key contributor to site leadership team responsible for defining, planning, and executing improvement projects across Engineering, Quality, and Planning departments.

Senior Project Leader / Development Engineer, 2010 – 2014

  • Managed diverse portfolio of orthopedic design projects and client groups. Projects included: implants and instruments for trauma, sports medicine, lower extremity, knees, shoulder, hip, and spine products. Responsibilities included sales, writing proposals, running projects, engineering design, engineering documentation, prototyping, V&V Testing, vendor selection, and design transfer.
  • Worked with engineers at large OEM and smaller start-ups to either provide full project management or engineering support as needed.
  • Worked directly with surgeon customers to understand market needs, develop and document product requirements, and define project scope.
  • Led multi-facility, cross-functional team to define and adopt a corporate wide design transfer procedure. Result: Authored SOP, secured executive team sponsorship, and trained 12 geographically dispersed manufacturing divisions.

FuelCell Energy, 2007 – 2010
An integrated fuel cell company that designs, manufactures, and operates stationary fuel cell power plants.

Senior Mechanical Engineer, Module Group

  • Identified and executed cost savings initiatives: design changes, DFM, and supplier management.
  • Led problem solving, material research, performance improvement initiatives, and new supplier development in North America and Asia.
  • Took a 3-week assignment in Zhuhai, China to develop vendor capabilities and ensure business performance objectives in cost and quality were met.

The Timken Company, 1996 – 2006
A global manufacturer of bearings and related anti-friction components.

Senior Application Engineer, Automotive Division, 2000-2006

  • Worked with Big 3 US automotive OEMs on new product development projects. Technical lead on several new business opportunities worth an estimated $20 million in sales annually.
  • Led technical team on strategic new-to-market advanced engine technology involving internal and xternal partners in Germany and UK.
  • Developed analysis results templates and trained other engineers and teams to ensure consistency in analytical results presented for new product costing models.

Project Metallurgist, R&D Division, 1996-2000

  • Consulted onsite and remotely with13 manufacturing plants located in Southeast US to reduce scrap and expand process capabilities. Trained and developed manufacturing engineers and operators to expand process capabilities and enable new product introductions. Developed and maintained strong internal networks. Results: Enabled new product offerings and reduced scrap exceeding $2 million.
  • Supervised Metallurgical lab team. Prioritized work, managed resources and developed people.
  • Researched, analyzed, and documented product failures using root cause analysis and materials expertise. Researched and analyzed new heat treating procedures. Tested and compared material characteristics from new suppliers to benchmark data to enable procurement cost reduction objectives.

Education

MS, Metallurgical Engineering, Colorado School of Mines, Golden, CO 1994-1996.  Thesis: “The Effects of Tensile Properties on the Dent Resistance of Automotive Sheet Steels.” Publication: SAE Paper 960024. Presented at SAE February 1996 Detroit Expo.

BS, Engineering, Mechanical, Colorado School of Mines, Golden, CO 1990-1994. Graduated with High Scholastic Honors.

Patents

  • US Patent 8871404 – Fuel Cell System Manifold Seal
  • US Patent 7010996 – Steering Column Clamping Device
  • US Patent D778,441- Fiducial Marker Support
  • US Patent D768,296 – Surgical Reference Clamp

Professional Development

  • Coursea, Google Specialization,  Google Advanced Data Analytics, February 2025
  • Coursera, IBM Specialization, Generative AI for Data Scientists, March 2024  
  • Coursera, University of Michigan, Statistics with Python, Specialization, July 2021
  • Coursera, University of Michigan, Applied Data Science with Python, Specialization, March 2021
  • ASM Global Materials Summit, Marco Island, FL December 2019
  • Ai4 Healthcare, New York City, November 2019
  • Ai4 Healthcare, New York City, November 2018
  • Flawless Consulting Workshop, Little Silver, NJ, April 2017
  • Dale Carnegie Leadership Training for Managers, Shelton CT, October-November 2015
  • CT Innovation Summit, Wallingford, CT, November 2014
  • ASME Project Management, Las Vegas, NV, September 2014.
  • AOSSM (American Society for Sports Medicine) Annual Meeting, Seattle, WA, July 2014
  • AAOSS (American Academy of Orthopedic Surgeons) Annual Meeting, New Orleans, LA, March 2014
  • NASS (North American Spine Society), Orlando FL, October 2010
  • TRIZ Basic Training, Danbury CT, February 2009
  • ANSYS CFX Computational Fluid Dynamics, Woodbury CT, August 2005
  • DFSS (Design for Six Sigma Training), Torrington, CT, June & July 2005
  • ProEngineering: Mechanisms Design and Analysis, Torrington, CT, August 2004
  • ANSYS Structural FEA Training, Woodbury CT, April 2003
  • ProEngineering: Advanced Part Modeling and Assembly, Torrington, CT, July 2002
  • Geometric Dimensioning and Tolerancing, Based on ASME Y14.5M-1994, Torrington, CT, 2002
  • DFMEA (Design Failure Mode and Effect Analysis), Torrington CT, September 2001
  • APQP (Advanced Product Quality Planning), Torrington, CT, November 2000
  • International Cold Forging Conference and Symposium, Stuttgart, Germany, September 2000
  • Project Management, Torrington, CT, June 2000
  • Tribology: Friction and Wear, Massachusetts Institute of Technology (MIT), Boston, MA, June 1998
  • ProEngineering: Basic training, Parametric Technologies, Westfield, CT, July 1997
  • TQM (Total Quality Management), Torrington, CT, 1996