Matthew Zalewski

Matthew Zalewski Email and Phone Number

Design Engineer @ Five Star @ Five Star Fabricating, Inc
Matthew Zalewski's Location
Twin Lakes, Wisconsin, United States, United States
Matthew Zalewski's Contact Details

Matthew Zalewski work email

Matthew Zalewski personal email

n/a

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About Matthew Zalewski

Hello! I'm a recent graduate from the Grainger College of Engineering at the University of Illinois at Urbana-Champaign (and current part-time Graduate student at the Whiting School of Engineering at Johns Hopkins), and I enjoy using computational methods to solve interesting problems! Outside of work and grad school I run a small trading operation.

Matthew Zalewski's Current Company Details
Five Star Fabricating, Inc

Five Star Fabricating, Inc

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Design Engineer @ Five Star
Matthew Zalewski Work Experience Details
  • Five Star Fabricating, Inc
    Design Engineer
    Five Star Fabricating, Inc Jun 2024 - Present
    Twin Lakes, Wi, Us
  • Vitesco Technologies
    Senior Mechanical Engineer
    Vitesco Technologies Apr 2024 - Jul 2024
    Regensburg, Bayern, De
  • Vitesco Technologies
    Mechanical Engineer
    Vitesco Technologies Apr 2022 - Apr 2024
    Regensburg, Bayern, De
  • Motorola Solutions
    Senior Mechanical Hardware Engineer
    Motorola Solutions Jul 2021 - Apr 2022
    Chicago, Il, Us
  • Motorola Solutions
    Junior Mechanical Hardware Engineer
    Motorola Solutions Jun 2019 - Jul 2021
    Chicago, Il, Us
    Motorola Solutions, Inc. provides data and telecommunications equipment for both commercial businesses and public safety. My role is to develop mechanical hardware for infrastructure, and my current responsibilities are:► Using PTC Creo 4.0 and Windchill for CAD to design sheet metal parts that house PCBA's► Using probability distributions to perform tolerance analyses on mechanical assemblies► Designing Heat Sinks and other thermal management solutions with PTC Creo and ANSYS Icepak for electronic components► Overseeing life cycles of parts and working with supply chain to push new parts to life stages► Prototyping and testing new designs using additive manufacturing, thermocouples, strain gages, etc.
  • Illini Motorsports
    Senior Rear Wing Design Lead
    Illini Motorsports Jul 2018 - Jul 2019
    Urbana, Il, Us
    For the 2018-2019 season, I passed on leadership to mentor the next team lead. This was done to promote a smooth turnover of leadership as well as ensure direct knowledge transfer between senior and junior members. I was responsible for:► Supporting the team lead with design and manufacturing responsibilities► Redesigning the rear wing to match the optimal track L/D ratio and shift the CP rearwardUnfortunately, we did not have the opportunity to validate CFD analyses through Wind Tunnel testing. However, the projected results were as follows:► <1% weight increase► 10.2%, 12.1%, and 6.1% rearward shifts in CP for Low, Mid, and High speed apex cornering scenarios► Point simulation indicates a need of 2.17 lbf of downforce for 1 lbm of weight gain for a part to be point-positive in competition. The redesigned rear wing generated 3.14, 6.23, and 5.8 lbf in downforce for Low, Mid, and High speed apex cornering scenarios, respectively
  • Illini Motorsports
    Aerodynamics Team Lead
    Illini Motorsports Jul 2017 - Jul 2018
    Urbana, Il, Us
    During the 2017-2018 season, I was the team lead in charge of 20+ students to create an aerodynamics package for the 2018 car. Our team was performing a major overhaul by switching out a space-frame chassis with a half-body carbon fiber monocoque and a rear subframe. The major challenge with this was adapting all the aerodynamic parts to fit the redesigned body. This involved several tasks:► Responsible for an aerodynamics CAD (PTC Creo) assembly model of 100+ parts and integrating that into the larger full car model► Quickly iterating airfoil designs in 2D using tools like JavaFoil and XFoil, and then moving onto 3D full car analysis using CFD (Star-CCM+)► Designing and analyzing mounting components using first order calculations supplemented with FEAFor the 2017-2018 car, we validated theoretical analyses with 2 full-scale wind tunnel testing sessions as well as on-track testing such as tuft testing and asymmetric oval lap times. Testing and analyses validated improvements to the aerodynamics package:► 11% increase in downforce with only a 0.67% increase in drag and a 3.68% increase in weight► 20% error between wind tunnel results and CFD
  • Illini Motorsports
    Radiator Cooling Lead
    Illini Motorsports Jul 2016 - Jul 2017
    Urbana, Il, Us
    During my sophomore year, my team lead discovered that we can save weight and double airflow to the radiator by removing the sidepods. My responsibility was to implement this change into the 2016-2017 car.
  • Illini Motorsports
    Sidepods Team Member
    Illini Motorsports Aug 2015 - Jul 2016
    Urbana, Il, Us
    I worked under the sidepods team lead where I mainly sanded carbon fiber, cut foam for machine molds, and other general fun new member activities.
  • Caterpillar Inc.
    Design Engineer Intern
    Caterpillar Inc. May 2017 - Aug 2017
    Irving, Texas, Us
    Caterpillar is the world leader in manufacturing mining and construction equipment, engines, industrial turbines, and locomotives. As a corporate intern, I worked in the Large Power Systems Division with the Advanced Engineering team on cooling products.The team I worked on was responsible for analyzing the fluid and thermal performance of new cooling designs for a range of different vehicles. In addition to analyzing new designs, they were also responsible for tuning analytical tools with experimental data to provide more accurate predications of cooling performance. As a part of this team, I worked on several projects:►CFD analysis on new radiator designs using ANSYS Fluent and relaying results back to the engineering team►Researched, created, and delivered a presentation comparing the efficiency of ANSYS AIM to an in-house software and proposed a solution to more effectively use both►Consolidated information from 15+ engineers to create a technology roadmap that got presented at a workshop for the cooling division►Used Business Analytics tools such as Microsoft Power BI and Tableau to contribute to an internal initiative that organized supplier data that saved several million dollars in company time
  • University Of Illinois At Urbana-Champaign
    External Outreach Chair In Engineering Council
    University Of Illinois At Urbana-Champaign May 2016 - May 2017
    Champaign, Il, Us
    During my time on Engineering Council, my job was to advertise the College of Engineering to high schools. This included: ► Organizing and presenting prospective and admitted student webinars consisting of 80+ students► Interacting with high school students and parents on engineering-specific tours► Advising the Director of New Student Programs within the engineering department.
  • University Of Illinois At Urbana-Champaign
    Bio-Inspired Adaptive Morphology Undergraduate Research Assistant
    University Of Illinois At Urbana-Champaign Nov 2016 - Mar 2017
    Champaign, Il, Us
    The BAM (Bio-Inspired Adaptive Morphology) Lab specializes in taking solutions from nature and applying them to mechanical and aerospace problems through robotics.
  • University Of Pretoria/Universiteit Van Pretoria
    Eng 398 Stem Projects Team Member
    University Of Pretoria/Universiteit Van Pretoria Jan 2016 - Jul 2016
    Pretoria, Gauteng, Za
    The purpose of this project was to develop soft skills working with students from other countries. While the course itself spanned several months, I was only in South Africa for three weeks to implement the projects. Unfortunately, the first project (an irrigation system) got burned down by protesters and we were forced to change plans, but the second involved facilitating a brick-making course for community members to start their own business.

Matthew Zalewski Skills

Matlab Python Carbon Fiber Manufacturing Ptc Creo Ansys Icepak Agile Plm Ansys Fluent Ansys Mechanical Strain Gages Star Ccm+ Jira Confluence Agile Project Management Flow Rate Fan Testing Geometric Dimensioning And Tolerancing Cadence Allegro

Matthew Zalewski Education Details

  • Johns Hopkins Whiting School Of Engineering
    Johns Hopkins Whiting School Of Engineering
    Applied & Computational Mathematics
  • The Grainger College Of Engineering
    The Grainger College Of Engineering
    Mechanical Engineering

Frequently Asked Questions about Matthew Zalewski

What company does Matthew Zalewski work for?

Matthew Zalewski works for Five Star Fabricating, Inc

What is Matthew Zalewski's role at the current company?

Matthew Zalewski's current role is Design Engineer @ Five Star.

What is Matthew Zalewski's email address?

Matthew Zalewski's email address is ma****@****ons.com

What is Matthew Zalewski's direct phone number?

Matthew Zalewski's direct phone number is +122461*****

What schools did Matthew Zalewski attend?

Matthew Zalewski attended Johns Hopkins Whiting School Of Engineering, The Grainger College Of Engineering.

What skills is Matthew Zalewski known for?

Matthew Zalewski has skills like Matlab, Python, Carbon Fiber Manufacturing, Ptc Creo, Ansys Icepak, Agile Plm, Ansys Fluent, Ansys Mechanical, Strain Gages, Star Ccm+, Jira, Confluence.

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