Product Engineering•Team lead consisting of 14 interdepartmental, cross-functional, members to design and develop vehicle powertrain system (motor, gearbox, and controller) from concept, to prototypes of increasing levels of fidelity, to high-volume (>150,000 units) pre-production in a startup company•System-wide component and assembly particulars (every last gram, millimeter, and joule accounted for)•Established cost targets for components, assemblies; including tooling and assembly line with focus on determining best design for component cost, mass and simplicity•Manufacturing techniques including 3D printing, billet machining, plastic injection, high-pressure die-casting, shell molding, sand-casting, and forging•Efficient utilization of 12 years of Pro/E, NX and CATIA with complex surface modeling, master-model concept, and BOM•Expert modeler in Pro/E and Catia V6 3D Experience, primarily surface modeler to create solid components•Complex system assembly design and integration of precision motor and gearbox housings, controller integration•Design plastic injection molded components and housings for mechanically constraining PCB’s, busbars, and associated connection methodologies•Experienced in supplier selection and qualification both locally and overseas for mass production•Dev. best-practice for GD&T methodologies for reduction in component cost while maintaining precision fit and extremely-low-to-zero waste, Cp and Cpk•Produce engineering drawings for casting, molded, forged, and machining components (and assemblies) conforming to GD&T ASME Y14.5Research and Development•Design Failure Mode Effect Analysis (DFEMA) and DVP&R creation for individual components and systems •Development, execution, and root cause system and component performance, durability and accelerated fatigue testing• Provide guidance, advice and mentoring to interns and earlier-experience engineers • Secured 2 Patents and Filed 5 Patent Applications for developed technologies

•Design (DFM protocol) and conduct FEA on various complex high-pressure die cast, sand cast, stamped and forged engine and support/structural components utilizing Pro-Engineer Creo 2, Unigraphics NX 7.5, or Solidworks 2012•Perform assembly FEA including bolted connection fretting (establishing cover factor), modal, component stress, fatigue, life, heat transfer and non-linear analysis utilizing ANSYS V14, FEMFAT, and internal-developed software.•Proficient in GD&T ASME Y14.5-2009•Develop 2 and 4-stroke engine friction model prediction and correlate to running engine (Haywood, Chen-Flynn, and regression modeling)•Research and create engine friction models for future engines and roadmap projections•Responsible for developing clearances, coatings and profiles for all contact surfaces inside 2-stroke diesel engines (i.e. journal bearings, piston profiles and skirt coatings, hone patterns and surface textures, piston ring face profiles and coatings, etc.)•Develop, write and conduct test plans on both AC and eddy-current dynomometers (Dynolab and TI Labview)•Assess repeatability of conducted tests to determine 95% confidence data•Proficient in C, Fortran, and Visual Basic•Design Front-End Accessory Drive (FEAD) systems using ProEngineer Creo 2 and conduct dynamic analysis using SimDrive•Coordination of manufacture and procurement of FEAD systems•Piston ring design, analysis (CK Engineering PROMPT software), and coordination of manufacture, procurement, quality and testing of ring components•Perform static and quasi-static analyses on pistons and piston rings using Ansys V14-16•Post-processing of analysis result and determining Factors of Safety using FEMFAT•Develop dynamic simulation model for EHD friction, NVH and 2ndary motion for engine pistons using Ricardo PISDYN and internal software•Perform DOE, response surface modeling and deterministic optimization for optimal designs using OPTIMUS or Design Expert•Conduct DFMEAs for parts/systems

•Developed and prepared Gasoline and Diesel piston models for analysis utilizing Unigraphics NX7.5, CATIA, or ProEngineer WF5 (CAD Software customer specified)•Developed 1D steady-state thermal or 2D transient thermal distribution boundary conditions for FEA based upon engine configuration or customer thermal data (I.e. Turbo/Supercharged or NA) utilizing in-house combustion and CFD simulation software CYLBOUN•Utilized Hypermesh V10 to design and optimize 2D tri-mesh for thermal boundary conditions, piston/bore contact, and pinhole stress analysis•Produced accurate and optimized 3D tetrahedron mesh for FEA•Post-Processed data results and determined Factors of Safety utilizing FE Safe V5.4 or FEMFAT•Developed dynamic simulation model for EHD friction, NVH, and Secondary Kinetic motions (DYCAP software)•Expedited preparation of presentations and reports•Performed DOE, response surface modeling, and deterministic optimization for optimal design and NVH performance using optimizers such as OPTIMUS•Produced engineering drawings for casting and machining components conforming to GD&T ASME Y14.5-2003•Assisted in the development of analysis techniques, standards, and systems. Formulated and implemented system design and analysis techniques and strategies to aid in concurrent engineering of powertrain systems•Developed, enhanced and maintained various in-house software including DYCAP•Developed customization software and macros for automation of analysis process to improve productivity of the end user•Worked in close conjunction with designers and application engineers in advanced product engineering for component and system based solution for various powertrain components, ensuring highest quality product combined with superior functional performance•Conducted BETA prototype development and testing of Nvidia Tesla cards for GPU heterogeneous supercomputing (hybrid FEA co-processing) using Abaqus 6.10EF (200-400% increase in analysis speed)

•Conducted gasoline, diesel and turbine engine dynamometer testing. Included assembly, setup test execution, teardown, and inspection/documentation•Performed dynamometer load/engine cycle design based on desired test parameters (design and I/O using MATLAB Simulink)•Performed accurate system component fatigue testing, NVH analysis, and emission testing using Horiba acquisition and Redline ADAPT Data acquisition•Conducted software code development for various test and design optimization methodologies in engineering design using MATLAB and C•Taught heat/mass transfer, thermodynamics, and cross-function mechatronics classes to undergraduate students•Designed, analyzed, built, and tested research thermoacoustic vapor-compression refrigeration system

•Conducted personal and group project management•Developed whole engine friction model by analyzing component specific contributions•Performed valvetrain component and system analysis/testing -familiar with Simulink, LabView, HBM, Tornado, and Rotec data acquisition systems•Performed accurate hydraulic deactivating lifter and camshaft phaser FEA analysis using ABAQUS and Unigraphics NX3•Performed new technology research and development with product feasibility and design utilizing DFM protocol•Performed journal/roller bearing friction, fatigue, and failure testing using prototype analysis methods •Conducted validation tests of prototype analysis methods and techniques through experimentation