Sam Morehead

About Sam Morehead

The energy and aerospace industries are at a pivotal point, facing immense challenges in achieving higher performance standards, ensuring system reliability, and meeting the demands of a fast-paced, innovation-driven market. Without innovative energy systems, streamlined workflows, and precise testing, companies risk operational setbacks, increased costs, and compromised safety.As a mechanical and systems engineer, I specialize in solving these pressing issues with a focus on energy system innovation, precision engineering analysis, efficient manufacturing processes, and testing expertise. Drawing from hands-on experience, I excel in analyzing, testing, and troubleshooting complex energy systems to ensure their reliability. My ability to streamline production workflows has not only reduced costs but also improved product quality. Additionally, my work in energy systems contributes to groundbreaking advancements, supporting next-generation energy and aerospace technologies that meet and exceed industry benchmarks.What’s most exciting about this field is the array of opportunities for innovation, including:1. Maturation of Metallic 3D Printing: New design options, and thus performance possibilities, are coming to life through the increased use of 3D printing in propulsion applications and other high-performance contexts that traditionally relied on subtractive manufacturing.2. Sustainable Energy Solutions: From alternative fuels to lightweight materials, there’s an ongoing revolution in making energy technology greener, reducing carbon footprints without compromising performance.3. Advancements in Hypersonic Propulsion: Hypersonic technology is reshaping defense and aerospace with its ability to travel at speeds exceeding Mach 5, enabling rapid global response capabilities and reducing mission timelines.What are the biggest challenges your team faces today? Whether it’s innovating energy or aerospace systems, optimizing production efficiency, or improving testing methodologies, I’m eager to collaborate on impactful solutions. Let’s connect and work together to drive energy engineering forward.

Experience

1. Senior Systems Engineer Commercial & Industrial Business Unit

   Generac

   Oct 2025 — Present · Waukesha, WI, US

   Generac Industrial Energy develops commercial and industrial generator and power management solutions that support data centers, critical infrastructure, and large energy users. I\'m responsible for leading the system architecture and integration of complex power systems, focusing on large-scale generator platforms and power management solutions for commercial and industrial customers.Key Responsibilities:• Power Systems Architecture: Leading end-to-end system architecture for commercial and industrial generator and power management platforms, aligning designs with performance, reliability, and compliance needs.• Requirement Gathering and Specification Development: Translating customer use cases, regulatory standards, and business goals into system-level requirements, interface definitions, and specifications for hardware, firmware, and controls teams.• System Integration and Validation Planning: Planning and coordinating system integration and verification activities across components and subsystems, including lab testing, field evaluations, and issue triage with cross-functional teams.• Cross-Functional Technical Leadership: Facilitating technical reviews, design trade-off discussions, and risk assessments with product, engineering, manufacturing, and service teams to keep designs on track with program objectives.• Process Documentation and Staff Mentoring: Creating and maintaining system documentation such as Statements of Requirements, block diagrams, and technical reports, while mentoring engineers in systems thinking and best practices.

Education

• The University of Texas at Austin

  Bachelor of Science - BS, Chemistry

  2009 — 2014

• University of Colorado Boulder

  Master's degree, Mechanical Engineering

  2019