Kyle Faller Email & Phone Number

Waterloo, Ontario

•Co-founded company to create zero-emissions capable engines for heavy duty applications, where battery and fuel cell technology is not feasible.•Developing patent pending valve-in-piston technology. Opposed piston engine with 4-stroke capability, variable displacement, variable compression, and variable valve lift characteristics. Capable of running traditional fossil fuels and switching to renewables (e.g. hydrogen, ammonia) on the fly.

San Francisco Bay Area

Team responsible for the mechanical design of drive unit rotors, rotor shafts, and stators. Worked primarily with stators. Part of larger team responsible for electric vehicle drive units.

San Francisco Bay Area

Responsible for powertrain durability tester project — a machine to carry out various durabilityand performance tests on electric motorcycle powertrain.• Manage overall project progress and input from other engineers/future users of the machine.• Mechanical design of frame, mounting structures, and inertial shock braking system, using staticand dynamic calculations, good engineering practices, and FEA methods.• Created over 100 parts and drawings using SolidWorks, and managed in SolidWorks PDM.• Research, quotation, and purchase of process chiller for accurate thermal control of machine.• Experience living and working abroad (San Francisco).

Waterloo Formula Electric builds a fully electric formula style racecar for competition against other Universities at SAE events. Founded in 2012, the team has built 3 hybrid-powertrain race vehicles before transitioning to full-electric for the 2016 season. We have received numerous performance and engineering awards for the innovative vehicles we develop.Powertrain Team•Managed powertrain sub-team: Regularly meeting with other leads to ensure seamless interaction of all vehicle systems, leading design discussions, delegating tasks, and developing sponsor relations.•Worked on testing of hub motors on engine dynamometer to obtain mechanical and thermal performance data in a controlled environment.•Design revisions of liquid cooling system and motor casing.•Designed and built HV connection enclosure for hub motor.•Assisted with development of wet rotor oil cooling system for hub motors.Aerodynamics Team•Designed and built wing mounting mechanisms.•Created foam and fibreglass molds and manufactured carbon fiber wings, nose cone, and body panels using hand layup techniques and resin infusion.

Dynaplas is a Tier 2 automotive supplier specializing in high-precision injection moulded plastic parts, designed to replace equivalent metal components.R&D• Design, development, and implementation of magnetic coupling driveline for pulley test machine, to reduce vibration and noise transmitted into test chamber.•Systematic testing, documentation of results, and analyzing data in various formats to find correlation between metrology data and pulley noise levels during operation.•Research of fluid dynamics and acoustics to devise a justified approach to development of a quieter pulley.•Installation and programming of PLC and HMI for more intuitive machine control, and implementation of safety and temperature sensing instrumentation.Manufacturing Engineering•Design and implementation of machine add-ons for improvements in automation, operator efficiency, and/or reduced production cycle time.•Design and construction of end of arm tool (EOAT) for part extraction from mold and de-gating.

Assisted technicians with automotive service and diagnosis on Mercedes-Benz vehicles. Performed regular maintenance service and assisted with engine and transmission work. Maintained shop cleanliness and high standards of Mercedes-Benz brand.