Responsible design engineer managing a small team for safety & fault handling of all modern Tesla drive units (inverters, motors, gearbox). My team's responsibilities include:- Monitoring, tracking, triaging, and addressing all drive unit faults occuring in the global fleet- Safety Response design/analysis/testing for all drive units, and their interactions with the vehicles high voltage bus- Drive unit fault response algorithm development and testing- New drive unit safety and fault response analysis, test plans, test execution - Field failure analysis, debug and design/FW mitigations

Principal designer of a solar powered 4-person car racing 3000km across the US in the American Solar ChallengeLed the development of the vehicle aerobody with a simulated CdA of 0.15, 4 times less than a Model S Driving the design of a hybrid carbon fiber and chromoly vehicle structure using ANSYS ACP and Static Structural Designed and led the manufacturing of a 16kWh battery pack (36s36p using 18650 Cells ) for last generation car

Designed a production insert molded assembly to improve the fault response capability of Model 3/Y drive invertersSupported the design and manufacturing of prototype Plaid powertrains for Model SAssisted the design, testing, and analysis of a small profile circuit breaker device Designed fixtures to test performance and reliability of M3 Drive Inverter design changes

Performed mechanical design for the model 3 battery pack focusing on product design for yield improvementsResponsible for the design of a sealed injection molded plug that increased battery pack first pass yield by ~1.5% Redesigned connectors to increase reliability by halving the install force while doubling the tear-out strengthLed root cause analysis to identify primary defects in assemblies that consistently failed leak tests

Designed adaptive fixtures to accommodate a range of 20+ smart glasses frame variants during final assemblyDeveloped tooling and processes for flex and rigid PCB install, gasket and adhesive placement and material handlingCreated detailed experiments to down select from over 15 thermal materials, resulting in $300k+ cost savings

Programmed, designed and assembled a PLC controlled panel for automated final systems verification of productDesigned mechanical parts in SolidWorks for manufacturing, field services and sensor mountingPrepared systems level electrical schematics in E-Plan P8