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.