Leading a team of all-star engineers to develop the next generation supermanifold/octovalve for Tesla's thermal systems.

Invented and led the design of the SuperManifold Assemlby (also called the OctoValve) for the Tesla heat pump system, now implemented across all Tesla vehicles.The SuperManifold integrates the thermal system into a PCB-like assembly which enables an efficient heat pump architecture while dramatically reducing cost and manufacturing complexity.The SuperManifold was a completely in-house design taken from concept to high volume production in 18 months.Led a mechanical design team working on components across all vehicle programs

Ramped production from 1200 to 5000 per week on the Model 3 thermal subassembly line. Redesigned equipment, optimized process flow, trained operators, and coordinated installations during shutdownsDesigned and helped fabricate a novel thermal system for the Tesla SemiDesigned and built a test buck for the Tesla Semi thermal system.

Designed the Model 3 chiller and expansion valve assembly (part of the SuperBottle), refrigerant lines, and thermal expansion valve

Started a company to design, manufacture, and market high-quality 3D-printed cookie cutters.Achieved a production scrap rate of <1% by systematically testing over 150 combinations of 3D printer settings, firmware configurations, and cutter profile designs to identify root causes of printing defects.Created a scalable manufacturing cell with multiple printers controlled by a web server hosted on a Raspberry Pi.

Collaborated with a small team of US engineers and an international joint venture to develop a high-pressure pneumatic brake system for freight trains operating in extremely harsh environments with extended service intervals.Designed and built prototypes for new products including extensive 3D modeling of parts for standard machining processes, injection molding, and sand casting.Developed test plans, and designed and built custom test fixtures for a DOE study of seal designs to validate performance at -60 C.Managed the implementation of a FaroArm and 3D laser scanner. Performed inspections of prototypes, mold tooling, production parts, and competitors' valves. Developed an in-house training manual for the FaroArm.

Worked with a large team of engineers to analyze documentation from 10,000 newly acquired cellphone towers to ensure prompt integration into the company database.Ensured the accuracy of tower data by comparing existing records to detailed field inspections.

Designed and built custom built-in furniture including entertainment centers, bookshelves, banquettes, kitchen islands, pantries, and bathroom vanities.Designed and remodeled kitchens, bathrooms, and basements including installing hardwood floors, granite tile counter tops, mosaic tile backsplashes, kitchen cabinets, appliances, and many custom cabinets.For more pictures, visit my Houzz.com profile:http://www.houzz.com/pro/jackcalderone

Performed calculations, equipment selection, and assisted with the drawings for a compressed air system at a military base . Project encompassed ten aircraft hangars, offices, and shop buildings.Analyzed a solar thermal heating system for a correctional facility including initial system design, sizing calculations, equipment selection, cost estimate, and payback analysis.Performed flow calculations for the replacement of a main steam header in the utility plant at MIT.Developed steam plant schematics for senior engineers to use in client interviews

Designed and built a mobile test facility for a military UAV engine including provisions for a fuel supply, an external cooling system, instrumentation, a control station with video monitoring, and a protective housing with sound attenuation. Performed all fabrication and test setup layout.

Designed and implemented extensive improvements to production, inventory, and packaging processes, increasing productivity and reducing shipment errors.Managed all in-house production including inventory tracking and raw material purchasing.Scheduled, trained, and supervised up to six employees during daily operations.Co-managed two significant warehouse system and layout overhauls which greatly improved workflow and maximized space in a crowded warehouse.