Aaron Smith Email & Phone Number

Howell, MI, US

Farmington Hills, Michigan, US

Farmington Hills, Michigan, US

Livonia, Michigan, US

• Define vehicle platform package architectural layouts in CAD to support all vehicle attributes, functionality, and component commonality targets.
• Developed three separate platforms with up to twelve vehicle options ensuring maximum cross product commonality.
• Perform feasibility checks in conjunction with functional module departments to ensure all styling surface releases meet the functional or attribute driven requirements.
• Support the Project Engineers in creating reference geometric packaging to meet attribute and functional targets implemented by the Vehicle Program team.
• Negotiate component location with PMT’s and functional leaders or engineers to achieve an efficient package, safeguarding customer space targets and protecting legal and functional geometric requirements.
• Create engineering designs and drawings to enable build and modification of physical package bucks.

• VLF Destino Supercar / Responsible for Powertrain, dry sump oil system, fuel system, exhaust system, cooling system, center console and all the CAD, CAE and supplier interface associated to each.
• Several Chinese OEM “Black Box” suspension developments performing design, CAE and multi-body dynamics work for: 1. Weichi 2. Zotye 3. Geely 4. SAIC 5. FAW 6. CODA
• Skyman / Twistbeam design, analysis and production prints.
• Mahindra / “Black Box” suspension development performing design, analysis, multi-body dynamics and production prints.
• DMI / Component design and analysis.
• EDAG / Frame fatigue analysis.

• Developed and maintained engineering change control system including procedures, documentation, file structure and data storage.
• Maintained CAD data module level releases
• Developed CAD data integrity standards and monitored supply chain for adherence
• Provided continual CG rollups for new releases at full vehicle and developed and updated the road map to deliver 5 star rollover performance
• Performed virtual builds based on vehicle assembly scroll to help develop robust assembly procedures and avoid any potential build issues
• Maintained and verified packaging and connections for all vehicle components

Troy, Michigan, US

• Black box suspension system development for small car project
• Developed an internal file structure and part numbering/naming convention to iterate designs quickly to assure fast and accurate design/development at pre-prototype stages
• Responsible for all CAD, stress and stiffness FEA and component optimization, print creation for the following components: front cradle, front control arm, rear twist beam, front stabilizer bar, springs
• Developed early g-loads
• Packaged entire “chassis system”, including: all structural components, struts and shocks, stabilizer bar system, steering, brake cable and line routing, brakes (rear, including ABS sensor and tone ring)
• Propose hard point and component packaging solutions to assure system performance targets were met

• Performed all DCX group FEA
• Performed all product optimizations (Optistruct/Design/FEA iterative loop)
• Design and FEA lead for most of Metaldyne’s knuckle, control arm & clevis programs
• Developed, analyzed, optimized, and detailed the following products for production release: DCX KA/KK front knuckle, front lower control arm (FLCA), front shock clevis; DCX DH front knuckle; Chery Automotive B23 rear.
• Developed, analyzed, optimized, and detailed the following products for prototype for cost savings: KA/KK Front Upper Control Arm – FUCA( redesigned from forged steel to D4512 cast iron), WK – FUCA (redesigned from.
• Developed, analyzed, optimized, and detailed the following products for production quoting: WD (FLCA, front &rear knuckle, FUCA, clevis, RLCA, rear knuckle), DS (FLCA, front knuckle)

Livonia, MI, US

• Interviewed, Hired and Managed as many as nine designers to develop the powertrain thru chassis for a government vehicle redesign quote.
• Design lead for all creation and refinements of all powertrain thru chassis components based on customer RFQ requirements including kinematics creation, tire envelope development and ground line creation
• Developed and organized data structure to cover large program scope
• Controlled data transfer to and from suppliers and customers
• Conducted full system clearance checks and design reviews with customer using Visview.
• Design Support for Ford Fuel Cell Development Program retrofitting current vehicle frame for tank, IPT and fuel stack mounting and packaging considerations.

New Boston, Michigan, US

• Design Lead for several variations of the Nissan Frontier, Xterra and Pathfinder production frames
• Design Lead for GMT265 and 295 production rear suspension modules
• Developed and detailed the GMT 265/295 modules and Nissan Truck/Suv frames from full assemblies down to component level parts based on lab testing, FEA results and manufacturing feedback
• Enhanced Nissan Truck/Suv designs for additional European vehicle variations with heavy duty loading
• Controlled data transfer to and from suppliers and customers for the GMT 265/295 modules and Nissan Truck/Suv frames
• Develop kinematics model for packaging and component articulation verification of the GMT 265/295 modules

Troy, MI, US

• Onsite Design Support at Tower Automotive for various suspension and underbody components

• Designed and detailed DEW98 halfshaft insertion assembly tooling
• Part and print design support for GMT800 lower control arm
• Design support for Carrlane Standard Parts Catalog