Thomas Busacca Email & Phone Number

Troy, Michigan, United States

Auburn Hills, Mi.

NVH - BSR Development Engineer responsible for identifying buzz, squeaks and rattles in pre-production Fiat & Chrysler automotive platforms and recommending engineering solutions.

Rochester Hills, Mi.

Engineer - Vehicle Development Specialist on the Bright Automotive IDEA PHEV. Responsible for validation of the product development strategy and technology selection which resulted in fundamental vehicle architecture changes that balanced market, function and business objectives. Lead engineer for the cross-functional vehicle attribute teams which were responsible for delivering engineering functional objectives, system descriptions and product requirements for Body, Interior, Chassis, Electrical & Powertrain engineering teams. Implemented processes and tools (PUGH, VoC Opportunity Matrix, QFD etc.) which utilized internal and external Voice-of-Customer (VoC) data, financial feedback, technical and vehicle perspectives, market research and executive leadership input which resulted in cost, weight and investment reductions of 20 percent.

Lead Engineer – Postal Truck Conversion to all Electric Propulsion Project leader for all engineering activities & communication between USPS and EDAG, Inc. for accelerated nine month project. Design manager responsible for all major systems and subsystems including all custom chassis and sodium-nickel (Zebra), battery technology from FZ Sonick Inc.Program Engineer – NHTSA Vehicle Lightweighting Program Responsible for evaluating, analyzing, and reporting to the NHTSA. Developed official report recommending materials, technologies and manufacturing systems to support future CAFE requirements.Vehicle Validation Engineer – Temsa TS35C Intercity Bus Performed market assessment of imported intercity bus to US FMVSS standards and applicable North American bus safety regulations. Responsible for coordination of all off-site testing, inspection and final report with itemized recommendations to bring vehicle into compliance.Research & Development Engineer – WorldAutoSteel Advanced Technologies Steel Car Administered project to develop a lightweight all-steel advanced technologies car with three unique propulsion systems; Battery Electric, Plug-In Hybrid Electric, and Fuel Cell.

Sterling Heights, Michigan

Core Airbag Engineering-Design, testing and validation of automotive safety restraints, including airbags and airbag inflators.Safety Restraint Test Engineering – Safety restraints systems and components Responsible for test engineering on the Chrysler RS DAB module. Responsible for project team testing of Occupant Classification System, (OCS), engineering development & testing, including Magnetostrictive, Capacitive, Infrared and Strain Gage technologies including extensive profile testing of human subjects and ATDs for analysis of form and weight based sensors necessary for automotive seat based sensor algorithm development.  Post-test data analysis of static and dynamic airbag module testing and analysis includes: Environmentally controlled airbag module deployments for deployment trajectory, vibration, sound and pressure envelopes, inflator pressure and generant curves and high speed motion analysis per FMVSS, OEM specifications and engineering performance standards.Test Equipment Quality Control Calibration and records maintenance of test lab equipment to A2LA and QS-9000/TS16949 accreditation. Instrumentation, calibration, repair, and maintenance of Hybrid III Anthropomorphic Test Dummies, (ATD’s), used in Hyge dynamic sled impact tests.

Calibration Practices & Techniques

Associate Of Science (As), Electronics Engineering & Robotics