Vancouver, British Columbia, Canada
Aerodynamic Prototypes
-Responsible for the leading, planning, and execution of Aerodynamic test programs for upcoming new vehicle programs, and for existing programs: Model Y, Cybertruck, Semi-Truck, Model S, Roadster -Lead programs organizing the work of over 20 stakeholders; including Engineers, Aerodynamicists Fabricators, Machinists, Painters, Composites, and Upper Management. Used tools to track project progress, health, and ensure that tight deadlines were met, highlighting major risks, and potential set-backs. -Designed, built, and tested components for Aerodynamic development and testing, using tools such as: 3DExperience (Catia V6), Catia V5. For analysis: Finite Element Analysis (3DExperience, Catia V5), and Computational Fluid Dynamics (Star-CCM+) -Assisted in the early development prototyping and design for new vehicle launches: Roadster (Interiors, Exteriors, Body/Frame), Cybertruck (Chassis, Exteriors) -Designed components for prototype manufacturing using methods such as: Rapid Prototyping, CNC Milling, Composites, Metal hand fabrication, welding, machining. -
-Overview the entire design process of the vehicle of all sub-teams, ensuring proper design choices are made including manufacturing & assembly processes, design justification, and test procedures -Responsible for improving the aerodynamics package to reduce weight of components and increase the coefficient of lift from -1.6 to -2.9 using CFD simulation (Star-CCM+), wind tunnel testing, and on-track testing -Created a robust and easily adjustable CFD Model using surface modelling in CATIA V5 -Designed structural mounting components and the body work using CATIA V5 and Solidworks -Responsible for the surface modelling design of the 3D-printed engine intake manifold using CATIA V5 -Teach lectures to team members on topics such as Aerodynamics, SolidWorks, and Engineering Design
-Responsible for the design of all driver-vehicle interaction components including the pedal box, braking system, steering wheel, dash, and seat -Managed a group of 6 mechanical engineering students and their associated sub-team projects -Designed a carbon fiber throttle pedal that reduced the weight by 35% from previous designs while exceeding strength requirements
-Designed stamped sheet metal components for the doors-in-white assembly for vehicle programs using surface modelling in CATIA V5 -Interfaced with suppliers to communicate changes, concerns, and recommendations on multiple components -Worked with various design and manufacturing engineers to come to conclusions in design decisions and directions -Performed different studies for dynamic clearances and packaging to assist in the design process -Designed stamped sheet metal components for the body-in-white assembly for vehicle programs using surface modeling in CATIA V5 -Worked with engineers in different departments and within Body Structures to resolve design constraints, and resolve packaging and performance issues -Handled requested changes from suppliers to the body structure during different phases of vehicle programs -Responsible for finding areas of joining concerns within the Body-In-White assembly, including documenting and communicating changes that need to be resolved
-Designed a 2.0’’ manual pull-activation air shut-off valve for diesel engine applications (PowerHalt Project) -Modeled and analyzed components using Solidworks Finite Element Analysis simulation package -Calculated, researched, and thoroughly tested single-stage reciprocating air compressor flow performance -Created and updated over 50 drawings for existing items in production and prototype projects