Thomas Bernacki Email & Phone Number

Twin Lakes, Wi, Us

Spring Grove, Il, Us

- Designed new quick-change tooling for Vertical Turret Lathes in order to reduce setup time required to reposition jaws on the table when securing round parts before turning operations- Designed new tool holder blocks for Vertical Turret Lathes to utilize CAPTO insert holders in order to reduce time spent changing inserts on the machine while ensuring insert location consistency when programming cutting operations- Developed heavy duty fixtures for supporting heavy forgings on a Horizontal Boring Mill machine- Created new safety walkway layout for Horizontal Boring Mill pit while referencing OSHA walkway, ladder, and fall protection safety standards- Developed fixtures, tooling, and parts for lifting and supporting large forgings for heat treatment- Created 2D drawings and 3D models in SolidWorks 2020 for internal use as well as for production by outside vendors- Completed Finite Element Analysis and hand calculations for stress analysis, fatigue analysis, and weldment strength analysis for new and existing fixtures - Developed new Ultrasonic Inspection process for the Maintenance Department to use ultrasonic flaw detectors to inspect for possible fatigue cracking on company press tie rods and pull back rodsAdditional Education:- Geometric Dimensioning & Tolerancing Class through McHenry County College, May 2021 - July 2021- Project Management Class, In-house, October 2020- SolidWorks Simulation Class through Computer Aided Technology, LLC, October 2019- Fundamentals of Rigging, through The Crosby Group, August 2019 - SolidWorks Essentials: Parts and Assemblies through Computer Aided Technology, LLC, July 2019

Major Project: involved with the panel restoration for the Mies van der Rohe United States Postal Service building - Developed designs and created 3D models in SolidWorks for furniture fabrication projects- Created furniture assembly instruction documents- Administrative responsibilities included corresponding with vendors and customers and utilizing QuickBooks software and Microsoft Suite- Studio skills included material measurements, cutting, sanding, finishing, assembling furniture items, and project management

I have been competing in auto racing since I was 9 years old. During my career, I performed setup adjustments on racing karts (chassis and engine tuning), I have analyzed vehicle telemetry obtained from racing karts and cars, and I have been competing mostly in SCCA Majors road course racing since 2013. I made my professional racing series debut in the Battery Tender Global MX-5 Cup Series debut in 2018. I competed at Road America during the Kohler Grand Prix and at Mid-Ohio during the Honda Indy 200. I finished in fourth in Global MX-5 Cup Challenge Event at Sebring International Raceway. Career Highlights:Car Racing2018: 4th in Global MX-5 Cup Challenge/ Made professional series debut in Global MX-5 Cup Series/ SCCA June Sprints T4 Champion/ 4 wins and 2 podiums/ 2 track records2017: SCCA Northern Conference T4 Champion/ 9 wins and 3 podiumsFinished 9th at the SCCA National Championship Runoffs at the Indianapolis Motor Speedway2016: 2 Top 6's in SCCA Majors events/ 1 win and 2 podium/ Tested MX-5 Cup Car2015: 5 Top 7's in SCCA Majors events/ 4 wins2014: 3 Top 8's in SCCA Majors events/ 3 wins and 7 podiums2013: Top 7 in SCCA Majors round/ 1 win and 5 podiumsKarting2012: MRP Rotax Senior Vice Champion/ 4 wins and 1 podium2011: Top 10 in Rotax Max Challenge Poland Round/3 wins and 4 podiums2010: MRP Rotax Senior Champion/5 wins and 4 podiums2009: MRP Junior Rookie of the Year/1 win

Chicago, Il, Us

- Developed design for the anti – roll bar- Created a 3D model in SolidWorks for visual representation of the design- Conducted Finite Element Analysis on the model in ANSYS by using stress analysis tools- Compiled initial documentation of proposed anti – roll bar designs, boundary conditions, decision matrices, and preliminary cost analysis- Assembled anti – roll bar prototype- Presented final anti – roll bar design to engineering judges at UIC Engineering EXPO

Charlotte, North Carolina, Us

- Developed designs for part and assembly modifications conforming to AAR and FRA standards for specific freight car classes - Documented design processes, reference drawings, and referenced AAR, FRA, and AWS standards for freight car modification projects- Created 3D models in SolidWorks for visual representation of freight car modification projects- Updated and developed official company 2D AutoCAD drawings of parts and assemblies of freight car equipment- Conducted modal analysis in ANSYS on 3D models to determine the natural frequency values for a proposed part modification- Edited and created maintenance instruction documents with instructions for completing modifications for specific freight car classes for Field Maintenance Operations

Union, Il, Us

Freight Car Department Volunteer- Worked with restoring corroded metal on freight cars and other pieces of railroad equipment- Worked with tools such as wheel grinders, needle chippers, table saws, band saws, and drills