Australia
Mechanical cell design engineer with experience designing and manufacturing lithium ion cells for electric vehicle, stationary energy storage and aerospace applications. Prior experience involves designing and manufacturing renewable battery energy storage systems.
Manufacturing high performance Li-S cells and Packs.
Leading the design of Dyson’s next generation cells
- Reported to the Director of Cell and Process Engineering & the Head of Cell Design. Drove technical meetings and design reviews for 21700 Lid, can, crimp and coil pack. Engaged with suppliers from Asia, the US, the UK and Europe. - Owned component, assembly, and process drawings/models for R&D to B-sample (21700). Led meetings and design reviews with process engineering, procurement, NPI Quality engineers and application engineering. - Supported all DMFEA and DVPR meetings for the cylindrical cell design. Used the DFMEA to define potential significant and critical characteristics (YS & YC) for all component and process drawings. Set up the 21700 BOM and added the data to Teamcenter. R&D project sponsor for Teamcenter set up and implementation. - Supported and reviewed the prismatic development program. This included requirements, testing, can & cap assembly designs and various termination designs. Prior to this produced multiple prismatic design concepts. - Produced concepts for ultra-high-power continuous tab applications (cylindrical). Activities included patent landscaping, engineering drawings, engineering calculations, DFMEA’s and process engineering. Supported tabless 4680 A-sample production and UN38.3 verification. - Completed the following training courses; Introduction to BS8888 and GD&T, APIS IQ (DFMEA) , Patsnap (patent landscaping) , DVPR and Teamcenter PLM management.
- Designed Prismatic Lithium-ion cells for grid balancing. This involved using hand calculations analysing Static mechanics, Stress, heat transfer and electrical calculations to verify designs. Used techniques such as Solidworks simulation, FMEA, P-diagrams, DFM, DFA to analyse components and assemblies. Successfully prototyped modules. This included selecting connectors, cables, fuses, cooling devices, busbars and anti-propagation materials.
- Supported the Technical Manager, Operations Manager and Quality Manager to ensure the manufacturing line met quality and technical specifications. Develop prismatic lithium-ion cells & BESS systems for Grid balancing. - Designed Prismatic Lithium-ion cells, modules, and racks for grid balancing. This involved using hand calculations analysing Static mechanics, Stress, heat transfer and electrical calculations to verify designs. Used techniques such as Solidworks simulation, FMEA, P-diagrams, DFM, DFA to analyse components and assemblies. Successfully prototyped modules. This included selecting connectors, cables, fuses, cooling devices, busbars and anti-propagation materials. - Learnt Equivalent circuit modelling (MATLAB) to analyse current, voltage, power and temperature rise of lithium-ion cells. Implemented my learning to predict the prismatic charge and discharge performance. - Owned all engineering drawings (BS8888), facility layouts and renders for all cell components. - Selected prismatic components and negotiated with suppliers. Worked with suppliers to produce prototypes for testing prior to mass production.