User Case Studies

Engineered prototype to production builds of three turbocharged flex-fuel (E85 – RON 92) off-road vehicles.
Validated & certified safety-critical SAE & ISO requirements for thermal, electrical, & mechanical systems.
Developed protective control logic with SMEs by defining lookup tables to adjust system output from inputs.
Refined fuel injection & ignition control strategies using Lambda feedback to satisfy EPA NOx emission limits.
Calibrated duty cycle maps to dynamically adjust boost pressure & maintain air-fuel ratio management.
Tested & optimized engine performance: engine maps, idle tables, ignition tables, throttle body tables, etc.
Led the introduction of positioning, navigation, & telecommunication for deployment of Starlink Systems.
Implemented media transmission systems with high-reliability & low-latency telemetry for live tracking.
Designed continuous engine to transmission power transfer system using centrifugal force clutching.
Engineered full engine/oil cooling loop subsystems to optimize heat rejection & increase thermal durability.

Modeled 3D parts: Instrumentation, digital display housings, cross-car beam, HVAC vents & ducting.
Identified FMEA parameters for components based on IATF 16949, AIAG & VDA industry standards.
Coordinated 3D DFM&A interference studies with sub-teams using 3D models & 2D cross-sections.
Designed & built studio model bucks & jigs to test in-situ environmental ergonomics & performance.
Engineered the electromechanical drive system for deploying & retracting the console CID touchscreen.
Selected suitable wiring, connectors, & shielding per device transmittals for COAX and TP harnesses.
Developed high specific strength TPC cross-car beam with minimized weight, deflection, & eigenfrequency.
Designed assembly line poke-yoke fixtures using kinematic coupling features to reduce TAKT time.
Automated 3D product data across 2,500+ parts & 1,000+ fields to maintain UUID structures for PDM/PLM.
Co-authored engineering drawings to communicate nominal geometry & allowable variations to suppliers.

Evaluated thermopolymer & thermoset tool CAD: ribbing, draft, thickness & shrinkage design standards.
Improved thermoset manufacturing cycle times while maintaining A-Class surface finishes (ηkWh ≈ 93.8%).
Characterized flexural bend strength (ASTM D790) of proprietary thermopolymer & thermosets.
Characterized interlaminar shear strength (ASTM D2344) of proprietary thermopolymer & thermosets.
Evaluated injection molding tolerances of hydrogen fuel cell collectors using LCMM (6μm precision).
Designed temperature controller: ATmega2560 controller, Max31588 breakouts, & K-type thermocouples.
Updated PDM system by creating & integrating CAD models (parts & assemblies) with ERP & PLM systems.
Authored electrical-mechanical schematics & engineering drawings (ASME Y14.100) for RFP, RFQ, & RFC.
Published ISO/TR 24666 & ISO/TS 24665 compliant installation manuals for product assembly SOPs.
Diagnosed key safety critical deviations & submitted NCR(s) to ensure ISO 17842-1 regulation compliance.