- Al-Al bolted joint torque spec derivation- Optimization of bolted joints for lighter material fastener replacement—Hand calcs w/ FEM verification in Simcenter NASTRAN- Designed tooling for in-house foam molding- Designed tooling for quick inspection of non-conforming parts to aid in material disposition prev 20% conforming after tooling >90% conforming- Designed spinformed components intended for production with analysis in Simcenter NASTRAN including initial conversations with multiple suppliers, DFM reviews, and supplier down select.- Created numerous part drawings conforming to ASME Y14.5 in NX- Worked to resolve design issues including transition from prototype-engineering grade SLA components to production aligned solutions - Explored solutions to improve engineering SLA component dimensional accuracy and decrease weight for use in experimental applications- Setup numerous solvent compatibility tests for adhesives and resins and pressure testing of components sealed with these- Evaluated and performed initial design of lightweight insert molded/ combination injection molding & urethane casting solution to replace a previously machined and bonded component- Developed a fastener testing methodology to validate torque specs precisely, allowing for preload verification down to +-30lbf increasing confidence on MoS of flight critical bolted joints.- Performed offshoot tests using this fastener testing methodology to validate impacts of two aviation greases, one with a traditionally used solid lubricant in solution intended for high pressure applications.- Performed offshoot tests during this study to evaluate residual preload after assembly to characterize preload losses prior to service and inform assembly procedure improvements.- Operated 3D-scan CMM to inspect incoming material and aid in design engineer’s disposition- Authored inspection reports for disposition and supplier review

Led the engineering efforts of ~80 person team through a one year design and production cycle. Led high-level decisions, managed timelines, and performed design/manufacturing work across all systems.

- Supported the development of vehicle dynamics simulations including a steady-state bicycle model lap time simulator and a Pacejka Magic Formula 5.2 tire model that was used to guide vehicle design and optimize vehicle performance.- Utilized SOLIDWORKS CAD to design the vehicle’s wheel assemblies which includes wheel hubs, uprights, brake rotors, and control arm pickups.- Performed FEA analysis and topology optimization on components using load data from vehicle dynamics simulations in both SOLIDWORKS FEA and ANSYS Mechanical structural analysis solver.- Applied knowledge of thermal cycling, material fatigue life, required part life and competition requirements to determine an appropriate factor of safety for components and make wheel bearing selections.

Data analysis, real-time data processing, optical measurements, test and evaluation, surface modeling and design for additive manufacturing.