Stan Lu Email & Phone Number

Kitchener, On, Ca

Waterloo, Ontario, Canada

Leading the development of new technologies and products to expand the product portfolio of Musashi North America. - Leading a newly formed advanced R&D team, building its foundations, defining team objectives and development roadmaps- Developing finite element analysis (FEA) models for ball joints, control arms, and differential cases. Correlating predictions to reality - Building a comprehensive material database through testing and characterization of automotive steels, aluminum

Waterloo, Ontario, Canada

- Responsible for research and development projects for enhancing fatigue performance, new manufacturing methods, sensor-embedded suspension components, 3D printing, new product development, and more- Developed 2 patent-pending technologies for automotive ball joints (electronics-embedded ball joint, and hyper-durable fatigue-resistant ball joint)- Conducted material characterization tests (tensile tests, fatigue tests) and post-processed results for FEA - Designed suspension components (Control arms, ball joints, knuckles) using CATIA

Waterloo, Ontario, Canada

- Designed suspension components (Control arms, ball joints, knuckles) using CATIA- Designed & assembled new test machines and fixtures with SOLIDWORKS to develop new durability and fatigue testing capabilities- Developed and conducted tests to assess the performance, strength, and durability of automotive suspension components- Automated test results analysis using Python, enabling rapid and consistent post-processing

Waterloo, Ontario

Modelled the constitutive behaviour of next-generation Ultra High Strength Steels (UHSS) in the UW Forming and Crash Lab.Characterized the plastic behaviour of boron steels at high temperatures and developed corresponding thermo-mechanical LS-DYNA (predictive simulation) models. - Conducted high-temperature (up to 900C) tensile tests with novel stereoscopic digital image correlation (DIC) techniques for full-field (surface) strain measurement- Processed experimental data with MATLAB to generate relevant material variables used in FEA (LS-DYNA) models- Conducted quasi-static tensile tests with DIC for full-field strain measurement - Characterized the coating evolution of coated boron steels at various stages during the hot stamping thermal cycle- Calibrated (finite element) material parameters by optimizing predicted results to match experimental observations with LS-OPT- Automated various workflow tasks using MATLAB (data processing, figure generation, results comparison) and Sikuli (image recognition to replace manual results identification)

- Teaching assistant for ME 322 "Mechanical Design 1"- Created video tutorials, responsible for answering student questions, grading projects and exams

Ontario, Canada

- Led the design process and planning of the all-new 2019 vehicle- Responsible for integrating all vehicle subsystem designs into a single operational assembly - Responsible for recruitment, finances, sponsorships, long-term planning- Machined/Manufactured numerous components of the vehicle including suspensions, driver controls, all sheet metal components, and miscellaneous parts

Markham, Ontario, Canada

Supported the design of various automotive components by predicting part performance using finite element analysis (Abaqus & LS-DYNA). - Conducted structural analyses (FEA) on various automotive components- Supported the development of a new suspension linkage by iteratively validating and improving its stiffness, strength, and fatigue life while accounting for costs, manufacturability, and packaging constraints. - Used Abaqus, HyperMesh (HyperWorks), nCode DesignLife to predict the performance of forgings, stampings, and weldments- Used LS-DYNA to predict the formability of various structural tubings

Waterloo, On

Supported the latest release of ANSYS AIM & Discovery Live by testing new features, and creating automated regression tests.- Created structural FEA and CFD case studies to benchmark and test ANSYS AIM 19.1- Wrote and maintained validation regression tests using Python- Conducted studies on mesh generation, mesh refinement, boundary layer formation

Kitchener, Canada Area

Diagnosed component failures from suppliers, internal manufacturing processes, and warranty claims using various metallurgical investigative techniques and technologies. - Performed failure analysis on failed components ranging from large weldments, cast parts, heat-treated axles and gears- Conducted hardness tests, sample preparation, microstructure analyses, case depth visualizations, and analyzed SEM micrographs

730 Rowntree Diary Rd.

- Updated PFMEA documents for pulley manufacturing processes based on ISO/TS 16949 principles- Redefined and narrowed the scope of internal DFMEA documents, assisted in the creation of a new work instruction on content generation

Master'S Of Applied Science (Masc), Mechanical Engineering

Computational and experimental research-based Master's student focusing on hot forming (press hardenable) steels, high-temperature.

Bachelor Of Applied Science (Basc), Mechanical Engineering

Activities and Societies: UW Baja SAE Student Design TeamGraduated 'With Distinction' and 'Dean's Honours List' 4 x Term Dean's Honour.