Designing AI hardware and wearables

Next-Gen Vehicle – Doors, Hard, & Soft Trims

• Lead engineer for the development of Doors, Hard, and Soft Trim commodities for a first of its kind vehicle.

• Defined project scope, and guided the design and manufacturing strategies to meet key performance metrics (safety, cost, mass, and quality) and international automotive safety regulations (FMVSS, IIHS, E/CN-NCAP, etc.).

Tesla Model 3 “Highland” Refresh – Hard Trims

• Managed full product lifecycle of Model 3 “Highland” Hard Trims, achieving 70% improvement in NVH, 15% part count reduction, 21% cost reduction, and 7% mass reduction while decreasing part quality rejection by 32%.

• Engineered safety-critical head impact components to meet FMVSS 201U requirements. Achieved 20%+ safety margin increase, and cost savings for Model 3, Model Y, and next-gen vehicles, totaling $30+MM per year.

• Collaborated with industrial designers to develop A-class surfaces, conducted concept studies in 2D and 3D, and led prototype trials. Developed CAD using Catia, completed DFM for various manufacturing processes, and oversaw 10+ global suppliers across NA, EU, MX, & APAC spending 20% of time on site.

• Managed 115+ engineering design/tool changes validating compliance and performance of all parts. Successfully launched vehicle production in 2 global factories, ramping to a total output of 12k+ vehicles per week.

• Lead Design Engineer for Model 3 and Model Y Upper Hard Trims.

• Achieved $8.8M in annual cost savings, 280 grams per vehicle in mass reduction, and part quality improvements through design modifications as part owner of 9 Hard Trim components.

• Raised a budget of $35k from several sponsors and recruited the largest ever team of over 45 students to design and build an all-wheel drive Baja SAE off-road race car

• Oversaw 7 leads ensuring organization and the timely completion of all deliverables while providing support to develop innovative designs in preparation for SAE sanctioned competitions across North America

• Provided members with guidance and mentorship for technical design challenges and approved all final designs and manufacturing plans

• Led a team to design and fabricate a double-wishbone front suspension and a trailing link rear suspension utilizing Solidworks CAD, FEA, and topology optimization

• Attended 4 major races across North America gaining experience working in the fast-paced, high-intensity, atmosphere of motorsport racing and leadership in various engineering environments

• Prototyped and fabricated various assemblies on the vehicle using CNC mills, lathes, 3d printers, and TIG welded the nose of the steel tube frame while mentoring younger members to gain hands-on experience

• Facilitated the training and certification of team members in the university manufacturing shop