• Enhanced and created methodologies for NPD and sensor layouts for model correlation and calibration based on test data, such as:o Created FEA analysis methodology to conduct NASTRAN and OPTISTRUCT linear modal transient superposition and correlate results with test data to ensure Structural Integrity of new designs.o Established FEA modeling guidelines to mimic MIG welds, bolted and flexible joint representations, and model organization for stress recovery.o Aligned nCode fatigue analysis solution cards with shaking table settings for improved vibration life predictions.o Leveraged ABAQUS explicit methodology to simulate and calibrate material damage initiation and evolution at different strain rates for HDPE.• Created detailed FE models in HyperWorks and ANSA pre-processors.• Interpreted Design specs, testing needs, Manufacturing and Assembly process barriers, and industrial design requirements, and translated them into detailed FE models. • Implemented alternative analysis approaches to tackle non-standard work.• Communicated FEA-based structural design changes (reports & recommendations) to diverse audiences, tailoring explanations for risk mitigation and solutions.• Conducted NASTRAN, ABAQUS, OPTISTRUCT, OPTIMIZATION, GlyphWorks, and DesignLife structural analyses of components and subsystems made of HSLA and SS steels, Al-alloy and Nodular Iron Castings, Composites, hyper-elastic, HDPE, HWMPE, PA polymeric blends.• Generated teamwork with design, test, industrial design, and manufacturing teams to establish action plans in compliance with program budget and schedule.Selected contribution• Optimized Muffler to Chassis fastener design, reducing hardware BOM from 16 to 3 pieces while maintaining structural integrity, vibration control, and assembly feasibility.• Significant advancement in motorcycle exhaust system validation performance: achieved 95% reliability with 90% confidence, up from 60% reliability with 50% confidence.

Consultant Sr. Finite Element Analysis Engineer • Established procedures to perform ABAQUS stress and Modal Analyses to replace parts made of steel with Fiber Reinforce Composites.• Created detailed FE models in HyperWorks and ABAQUS-CAE using STEP-CAD geometries.• Led USA and France FEA modeling teams to idealize real-world problems into practical FE models.Selected contribution• Achieved a 23% mass reduction in semi-truck hoods by substituting steel material for composite.

• Support New Product Development (NPD) of vehicle subsystems by developing structural simulation models supporting requirement verification: Structural Integrity.• Delivered data-driven structural design recommendations based on comprehensive FEA Structural Analyses in time and frequency domains, considering regular, abuse, ultimate, fluid-structure interaction, and fatigue loads. • Utilized NASTRAN, OPTISTRUCT, ABAQUS, and nCode-DesignLife to perform inertia relief, linear and non-linear static, modal transient superposition, non-linear transient solutions, and fatigue life predictions for assemblies comprised of various materials.• Elaborated detailed FE models using HyperWorks, and ANSA, and defeatured CATIA geometry. • Automated HyperMesh FE modeling tasks for stabilization bars using TCL/TK scripts, improving modeling efficiency.• Mentored Junior engineers to land physical problems into feasible simulation models to deploy robust design recommendations.• Correlated simulation models with test data using nCode suite. • Processed digital signals: (strains, accelerations, etc.) for simulation purposes.• Communicated FEA results to multidisciplinary teams to support design, manufacturing, and physical test validation activities, ensuring successful product development.Selected contribution• HyperMesh FE modeling of stabilization bars, slashing modeling time by 90% with TCL/Tk scripts.

• Supported the New Product Development process (NPD) to ensure they meet specs.• Delivered FEA data-driven design recommendations, and wrote and discussed reports with diverse teams to resolve manufacturing, validation, and quality troubleshooting. • Conducted NASTRAN, OPTISTRUCT, and ABAQUS Fatigue studies with assembly, operating, and thermo-mechanical loads.• Leveraged classic hand calculation results for problems for preliminary evaluations.• Interpreted measured test data to correlate simulation models.• Elaborated detailed FE models using UNIGRAPHICS to defeature geometry before meshing it in HyperMesh. Target solvers were NASTRAN, OPTISTRUCT, and ABAQUS. Among the analyzed subsystems comprised of various materials were chassis, bodies, engine assemblies, seals, doors, exhaust systems, etc. at required design reviews of PLM.• Estimated High Cycle and Low Cycle Fatigue life (durability) in time, and Frequency domains. Selected Contributions:• Reduced 90% of MIG weld modeling time by developing TCL/TK scrip.• 80% savings in modeling of customized bolt joints with TCL/TK scripts.• Reduced 60% NASTRAN channel load definitions by using C-language script.

• Provided simulation support to New Product Development (NPD) to meet technical requirements.• Created CAE manpower plans and assigned tasks to each team member. Mentored Junior engineers. Executed technical revisions before delivering results to customers. Ensure tasks are performed on time and in compliance with the program schedule.• Created 3D full parametric Unigraphics solid models for FE model generation. Constructed detailed FE models in ANSYS mechanical. • Evaluated stiffness, thermo-coupled stress, and fatigue of aircraft, industrial, and marine turbine engine cases due to fatigue loads using ANSYS, hand calculations, and in-house fatigue software.• Implemented Six Sigma (DMAI) methodology to improve the daily basis design process. • Performed GD&T-based tolerance analysis for cold & hot stack-ups of non-conforming aerospace parts during the Material Review Board (MRB) evaluation.Selected Contributions:• Award-winning annual nomination to the GEAE Global Engineering Excellence Award.