Michael Foos Email & Phone Number

Los Angeles, Ca, Us

Hawthorne, California, Us

Hawthorne, California, Us

Hawthorne, California, Us

•Designed critical flight hardware and tooling for Starship & Super Heavy Booster with a focus on sheet-metal structures, 3D modeled in compliance with aerospace standards and specifications in Siemens NX. Generated detailed engineering drawings utilizing GD&T.•Optimized components and assemblies for various manufacturing processes, including CNC, lathe, laser-cutter, waterjet, brake-form, and welding processes (spot weld, fusion weld, laser weld). Traveled to production site to oversee integration of hardware on-vehicle.•Managed large part release workflows and change processes through Siemens Teamcenter PLM, requiring effective communication with cross-functional teams of engineers.•Maintained and updated large flight-vehicle assembly CAD. Released revisions and created detailed assembly drawings.

• Responsible for the leadership of all mechanical and electrical sub-teams as well as the design and integration of electromechanical systems across Yale's FSAE vehicles.• Latest Project: owned design of entire chassis and suspension for formula-style EV from concept to production, involving novel 3D-printed aluminum-alloy uprights (generatively designed) as part of capstone engineering project.

•Mechanical design team lead with a focus on aerodynamics and vehicle body structures.

Austin, Texas, Us

Battery structures design for the Model S Plaid:•Owned redesign of injection molded seals for Model S Plaid battery pack from concept phase through to sampling and testing.•Used CATIA V5 to design structures components and created 2D drawings for suppliers utilizing GD&T.•Rapidly prototyped design iterations through combination of FDM and SLA printing.•Performed line-side quality inspections and worked with test engineers to validate design decisions.• Actively sourced and communicated with overseas suppliers while performing design for manufacturing (DFM).

Austin, Texas, Us

Battery module/pack manufacturing for the Model 3 and Model S Plaid:• Designed and realized custom manufacturing fixtures and electro-mechanical equipment using SolidWorks 3D CAD and created 2D drawings utilizing GD&T.• Performed data analysis to identify problem root causes and rapidly prototyped solutions critical to production cycle time and yield.•Laid out production workstations for product flow, ergonomics, and efficiency while generating process documentation, manuals, and specifications.•Managed purchasing and inbound/outbound shipments for various volumes of production.

New Haven, Ct, Us

• Researched and designed a new centerboard for collegiate racing sailboats to increase efficiency and handling in the water.• Learned and practiced fundamentals of hydrodynamics and CFD.

New Haven, Ct, Us

B.S., Mechanical Engineering (Abet)

Study Abroad - Summer