Summary
Highly analytical and innovative Mechanical Design Engineer with 6 years of experience in product development, manufacturing, and advanced engineering analysis. Proven ability to lead design projects from concept through production, optimizing for performance, cost, and manufacturability. Adept at leveraging CAD/CAE tools and FEA simulations to solve complex engineering challenges and drive significant product improvements, consistently delivering robust and efficient solutions.
Experience
Senior Mechanical Design EngineerFord Motor Company
- Led the design and integration of powertrain components for next-generation electric vehicles, reducing part count by 18% and assembly time by 15%.
- Utilized advanced FEA techniques (ANSYS) to analyze structural integrity and thermal performance, achieving a 25% improvement in component lifespan.
- Managed cross-functional teams of 5 engineers to deliver design solutions on aggressive timelines, consistently meeting project milestones.
- Implemented DFM/DFA principles, resulting in a 10% reduction in manufacturing costs for critical engine components.
- Mentored junior engineers in CAD modeling (CATIA V5/V6) and simulation best practices, enhancing team productivity by 20%.
Mechanical Design EngineerBosch
- Designed precision mechanical systems and components for automotive sensors, achieving a 99.8% reliability rate over 50,000 operational hours.
- Performed extensive tolerance stack-up analysis and GD&T specification for complex assemblies, reducing manufacturing defects by 12%.
- Collaborated with manufacturing partners to optimize component designs for high-volume production, contributing to a 5% unit cost reduction.
- Developed and executed comprehensive test plans for new product validation, ensuring compliance with automotive industry standards.
- Contributed to 3 successful product launches, from concept phase to mass production, exceeding performance targets by 10-15%.
Projects
EV Battery Pack Thermal Management System
- Designed and analyzed a novel cooling plate design for high-density EV battery packs, improving heat dissipation by 20% using CFD simulations.
- Reduced manufacturing complexity by 15% through design consolidation, leading to a projected cost saving of $5 per battery module.
- Led experimental validation of prototype thermal performance, achieving target temperature uniformity within 20C.
Autonomous Sensor Mounting System
- Developed a robust mounting system for LiDAR and camera sensors for autonomous vehicles, passing extreme vibration and environmental tests.
- Optimized material selection and geometry to achieve a 25% weight reduction while maintaining structural integrity.
- Collaborated with electrical and software teams to ensure seamless integration and sensor calibration accuracy.
Next-Gen Engine Component Redesign
- Redesigned a critical engine component for a 1.5L gasoline engine, resulting in a 10% reduction in overall component weight.
- Performed detailed fatigue analysis using ANSYS, extending component lifespan by 30% under cyclic loading conditions.
- Reduced manufacturing scrap rates by 8% through improvements in GD&T specifications and collaboration with tooling engineers.
Education
University of Michigan - Ann ArborM.S. Mechanical Engineering
- Specialized in advanced mechanics and materials science with a focus on automotive applications.
- Developed an optimized thermal management system for electric vehicle batteries, reducing temperature variations by 15% in simulations.
- Published a thesis on fatigue life prediction for additively manufactured components.
Purdue UniversityB.S. Mechanical Engineering
- Graduated Summa Cum Laude with a GPA of 3.9/4.0.
- Awarded the Dean's Scholarship for academic excellence for four consecutive years.
- Led a senior design project to develop an energy-harvesting shock absorber, achieving 20% energy recovery in lab tests.
Publications
Fatigue Life Prediction of Additively Manufactured Components under Multi-Axial Loading
Optimized Thermal Management for High-Density Electric Vehicle Battery Packs
Impact of Advanced Manufacturing Processes on Component Performance in Automotive Applications
Skills
CAD Software
CATIA V5/V6SolidWorksPTC CreoAutoCADFusion 360
CAE & Analysis
ANSYS MechanicalABAQUSNastranFEACFDThermal Analysis
Design & Engineering
DFM/DFAGD&TTolerance AnalysisPrototypingDesign ValidationMaterial Selection
Manufacturing Processes
Injection MoldingSheet Metal FabricationMachiningAdditive ManufacturingAssembly
Programming & Tools
Python (Scripting)MATLABJIRAMicrosoft ProjectSAP