o Coordinated subsystem projects and ensured design and manufacturing timelines were upheldo Contributed fresh and innovative design ideas to shifting mechanisms for both the driver interface and internal gearbox components by introducing over-center linkages for integrated locking and adaptive mechanical advantage, resulting in vastly increased reliability and ease of use in adverse terrain conditionso Designed a fully custom front differential casing and associated mounting to significantly reduce overall weight (over 40% dry weight savings, augmented by reduced oil volume) and improve ease of maintenance and manufacturabilityo Implemented a novel sliding differential mounting bracket system to eliminate jigs, using a 3D-printed differential casing and gears for bracket alignment, increasing location accuracyo Drafted and coordinated the manufacturing of shifting mechanisms and front differential componentso Performed extensive FEA analyses of all critical components for multiple use cases

o Oversaw and directed a team of seven members to extensively redesign the Pedals subsystem, including driver interfaces such as the gas and brake pedals, driver protection such as differential guards and the heel rest, and the vehicle’s throttle assemblyo Implemented a significant (15%) reduction of the total mass and part count of the subsystem, while increasing functionality, enhancing ease of maintenance and improving ergonomics and controls sensitivityo Arranged for the drafting and subsequent manufacturing of all components within the subsystemo Acquired extensive experience with Siemens Simcenter Nastran FEA software throughout the design process

o Singlehandedly acquired an industry sponsorship to design a custom 3D-printed user interface for the Shifter subsystem, which included photogrammetry software and mesh-to-NURBS resurfacing technologyo Led a successful comprehensive restoration of the team’s 2019 car to competition standardso Designed a retrofitted driveshaft guard for the team’s 2022 car using Siemens NX

o Entrusted with Controlled Goods Program security clearance to support the Mechanical Engineering & Prototyping team using fundamental engineering principles, theories, and practiceso Designed (using Solidworks) jigs and fixtures for rapid prototyping, testing, and user evaluationo Created CAD drawings and BOMs (using Solidworks) for new and existing jigs and fixtureso 3D printed key components with a Stratasys FDM industrial printero Machined aluminum and steel parts for jigs and fixtureso Maintained and swapped materials and toolheads on a Stratasys FDM industrial printero Post-processed and finished 3D printed prototypeso Probed 3D printed and machined components with a FaroArm CMM and PolyWorks softwareo Created and conducted presentations for technical reviews

o Designed (using Solidworks) and built jigs to improve technician efficiency and ease of maintenanceo Reviewed and edited tooling equivalency documents for discrepancies and errors across hundreds of CMM's (component maintenance manuals)o Used Microsoft Excel to analyze financial data concerning maintenance order quantities, revenues, and profits for capital expenditure discussionso Designed (using Solidworks), built, and tested fixtures as per CMM requirements to test various aircraft componentso Trained maintenance technicians to use various jigs and fixtures designed for component testing purposeso Produced proposal and cost analysis documents to justify and secure the company's acquisition of new engineering technologieso Developed detailed procedures for scan-to-CAD conversion to be used in reverse-engineeringo Trained engineers to use 3D scanning for reverse-engineering processeso Researched and found commercial sources for hard-to-find components and chemical products, as well as suitable replacements for those that were unavailable for purchaseo Produced comprehensive testing sheets for new test rigs as per specific testing procedures contained within various CMM'so Wrote detailed process manuals used for training purposeso Used 3D scanning and traditional metrology to generate accurate and precise CAD models of various 3D-printed fixtures and components

o Singlehandedly conceived and manufactured an adjustable 3D-printed jig that allowed a standard chop saw to make perfectly square cuts through 6-inch-diameter carbon fiber body tubes with Ultimaker Cura and Siemens NXo Developed and fabricated an adjustable vertical display stand for a 15-foot-long competition rocket, capable of accommodating future rockets of varying heights and diameters, as well as withstanding desert heat for extended periods of time, using Ultimaker Cura and Siemens NX

o Designed a component of a planetary gearbox that solved a critical design flaw using Siemens NXo Drafted numerous gears and related components for manufacturing with Siemens NX

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