David Castro Email & Phone Number

Milford Charter Township, Mi, Us

College Station, Texas, United States

College Station, Texas, United States

• Led braking system design, developing a braking system calculator in Microsoft Excel to size brake system components matching vehicle weight transfer during braking and providing correct proportioning of brake force to lock-up all 4 tires. • Designed brake pedal assembly, employing a horizontal master cylinder arrangement to ensure pedal is set at 90 degrees relative to master cylinders to prevent over-center, with adjustable pedal ratio of 4.73, 4.02, or 3.44.• Employed SOLIDWORKS and SOLIDWORKS FEA to optimize weight and stiffness of a brake pedal arm, achieving a FOS of 5.5 and a maximum deflection of 1.2 mm under a 2000N applied force, with a weight of 0.37 kg.• Collaborated with manufacturing team members to implement DFM principles, assuring design feasibility and enabling brake components to be manufactured using waterjet, manual mill, and manual lathe.• Verified braking system performed to design specifications, successfully passing brake test at FSAE Michigan and exhibiting no reliability issues during dynamic events, with drivers expressing satisfaction with system's feel.

Dearborn, Michigan, United States

• Managed physical front end build of future property through digital representation, addressing design engineer’s concerns with frunk loading and part complexity based on different vehicle control models. • Built digital representation of vehicle front end in Siemens Teamcenter, identifying 577 different part assemblies across 3 build combinations needed for property build, creating a filterable Excel BOM list for Roush Industries. • Performed Digital Pre-Assembly (DPA) checks in Siemens TcVis, evaluating clearance to and from parts, working with design engineers to concur that parts below minimum clearance were of design intent. • Filed patent innovation through Ford for a regenerative anti-roll bar device for use on electric vehicles to extend range. • Collaborated with Virtual Vehicle team to develop a deep understanding of data flow in Ford’s digital build process.

Lisle, Illinois, United States

• Investigated returned EGR value parts with a fellow team member, conducting part teardown and diagnosing failure mechanism. Identified coding error within testing program which resulted in input figure being off by a factor of 100. • Analyzed department project workflow from escalation to de-escalation, investigated communication and information exchange shortfalls by consigning team members’ concerns, and organized a department improvement plan. • Initiated and coordinated development of a one-pager report format, tracking project timelines, key actions, and roadblocks, increasing efficiency of project communication between U.S. and Mexico-based departments.• Developed PowerBI dashboard of warranty part return data, linking two separate databases containing 50,000+ individual claims together, resulting in an easily accessible and searchable tool which reduced loading times by up to 50%.• Acquired experience in root cause analysis and statistical problem solving, utilizing new tools such as PowerBI, Impala, and Hue.

College Station, Texas, United States

• Accepted as an EV Apprentice through my experience as part of the SAE Development team the year prior. • Gained valuable experience in the design, implementation, and manufacturing of suspension components, learning how engineering principles apply in the real world. • Helped with the manufacturing of suspension components learning how to use machines such as the lathe, mill, and waterjet. • Understood how to work within a multi-team environment, where differing sub-team needs had to be considered and addressed. • Created the final visual design of the 2023 FSAE EV car with fellow design team members. Collaborated closely with the overarching team to develop a visually striking and functional final livery, that met rule requirements and sponsor requests.

• Tasked with optimizing a track width for a formula car with given specifications along with deriving a control arm load calculator as part of the Texas A&M Formula SAE Development team. • Worked with two other student engineers to develop calculation tools and optimization techniques. • Presented project to senior engineers in an engineering presentation format, outlining development, key findings, issues during development, and future considerations. • Developed critical working skills such as “learning how to learn”, time management, and teamwork alongside both technical math and theory.

Azle, Texas, United States

• Readied the lobby area and menus for business prior to opening including stocking candy area, wiping down menus, and learning waitstaff stations as well as keeping the lobby area clean during business hours. • Handled all types of transactions regarding the payment of guest checks whether by cash, charge, gift card, etc.• Answered phone, taking care of guest's to-go orders, questions about the business, and helping out with customer's requests ensuring satisfaction with food and service.• Developed a positive working relationship with all food service employees and worked as part of a team by helping others as needed or requested.• Greeted guests in a warm friendly manner, welcoming them into our restaurant, creating a good first impression.