Munich, Bavaria, Germany
Spearheaded the mechanical design and prototyping of a novel immobilizer mechanism for an e-bike drivetrain, leading to a successful patent application. Led the end-to-end development of an innovative e-bike drivetrain, encompassing concept evaluation, mechanical design (in collaboration with external partners), prototyping, and testing. Key responsibilities included: - Advanced mechanical design. - Gearing calculation and specification for manufacturing. - Generation of comprehensive technical drawings, including Geometric Dimensioning and Tolerancing (GD&T). Conducted in-depth analysis and resolution of customer-reported issues related to a handlebar control unit. The process involved: - Lab testing to reliably reproduce the reported failure mode. - Detailed mechanical and electronic analysis of the product design. - Proposal, rapid prototyping, and testing of potential corrective solutions. - Implementation of the final fix in coordination with the external manufacturer. - Post-rework product testing, resulting in a significant reduction of the failure rate from 25% to under 5%.
- Work on mechanical concepts and product development in close collaboration with the design team - Prepare CAD models and technical drawings of all components - Execution of DFM, verification of assembly and tolerances - Development and realization of early device prototypes - Evaluation of engineering validation test builds and interfacing with plastic component suppliers - Development of functional test rigs for device EOL and lab testing
- Development of mechanical test setups for Smart Thermostats - Preparation and execution of mechanical tests for Smart Thermostats - Development and implementation of boiler testing platforms - Battery runtime and energy consumption analysis - CI/CD testing environment implementation - Analysis of customer support cases and warranty replacements
- R&D for Roll Forming applications - FEM analysis with MSC Marc/Mentat and COPRA FEA RF - Roll forming design with COPRA RF - Material characterization - Customer relations - Technical support - User training - Development of software documentation and training materials
"Roll Forming – a study on machine deflection by means of experimental analysis and numerical developments" - Finite element analysis of a roll forming process - Design of a roll forming machine to perform experiments - Design of a measurement system for acquisition of deformations, strains and forces - Development of new simulation strategies for dealing with machine deflection
- Basic training on the operation of COPRA FEA RF - Revision and update of user documentation - Finite element analysis of roll forming processes