Alec Castro Email and Phone Number

• Collaborated with a team of 10 engineers to redesign the rear suspension system to adapt to the team’s first electric vehicle.• Performed FEA analysis on various suspension components using ANSYS to achieve above a factor of safety of 1.5. • Redesigned front and front rocker arms using SolidWorks to achieve motion ratios of 0.80 & 0.85 respectively with varying ride adjustment points, all while maintaining a maximum deflection target of 0.010.• Performed fatigue analysis using ANSYS on Hubs for max braking event of 2.2G’s to justify component carryover. • Designed front and rear anti roll bars for 85lb-ft/deg & 45lb-ft/deg respectively to achieve weight gradients of 62.5lb-m/g & 63.8lb-m/g while maintaining vehicle balance during corners. • Performed validation Instron pull testing on front and rear suspension linkages to achieve above a factor of safety of 1.4• Calculated ideal front and rear ride frequencies of 137.5 cpm & 128.7 cpm respectively to improve vehicle stability. • Modified Ackermann steering configuration to increase Ackerman factor from 23% to 45% increasing yaw moment & reducing time by 0.10 seconds during low-speed turns, contributing to a 50-point increase. • Iterated through kinematic point simulation to select new inboard mounting points, achieving a motion ratio of 0.85 that reduced vertical wheel travel and increased the vehicle stability.• Developed control arm load matrix solver for 2.0g lateral acceleration & 1.2g longitudinal acceleration load cases to reduce weight across components by 15%.

• Developed a reconfigurable multilayer microelectronics package using narrowband and wideband filter technology.• Designed a multi-layer Printed Circuit Board to house narrow band and wide band filters along with other microelectronics.• Performed dimensional and statistical tolerance stack up for x y and z dimensions of a High-Density Interconnect PCB. • Designed Hight Density Build Up interposer to fan out RF, voltage and controls signals across a 4-pole single throw switch onto an HDI interposer.• Generated various PCB stack ups using laminates such as Megtron 7N, Rogers 3003 along with varying prepreg & copper thicknesses. A focus on dielectric constants and producibility capabilities were heavily considered. • Using AutoCAD had created artwork for switches, HDI, HDBU, SOI chips, and a multitude of other microelectronics.

• Designed and modeled a combustor testing fixture focused on CO2 recapture using NX.• Designed axial constraint support structure to react to 8000lbs of thrust produced by combustor.• Implemented thermal compliance features to prevent shear stress on rig support fasteners. • Performed modal analysis on exhaust components for turbine engine using ANSYS to locate cracking regions.• Redesigned cold section structure for gas turbine engine using NX to eliminate LCF cracking. • Developed integrative solutions on critical aerospace components for commercial and defense companies.• Designed adjustability into test stand to manage tolerance stack ups and manufacturing defects. • Constructed design matrices to quantitatively compare feasibility, modal avoidance capability, etc. across different solutions. • Analyzed manufacturing tolerance stacks on assembly modules to validate preliminary root cause analysis