Lewis Gross
M.A.Sc. – Mechanical Engineering candidate specializing in EV battery systems, thermal management, and high-voltage battery integration
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About
M.A.Sc. – Mechanical Engineering candidate specializing in EV battery systems, thermal management, and high-voltage integration with experience leading multidisciplinary engineering teams in the North American Battery Workforce Challenge. Proven background in mechanical design, prototype development, thermal simulation, DFMEA, and validation testing for award-winning battery pack and BDU systems developed alongside industry partners, including Stellantis, Argonne National Laboratory, AVL, and EATON.
Experience
Engineering Manager at McMaster Battery Workforce Challenge (2024-01 – Present)
- Personally recognized with the 2025–2026 Excellence in Leadership – Engineering Management Award by Argonne National Laboratory for fostering outstanding technical performance, collaboration, and team culture.
- Directed three multidisciplinary engineering teams across vehicle integration, hardware, and software development for a state-of-the-art EV battery pack designed for the 2024 RAM ProMaster EV.
- Delivered technical design reviews and presentations to industry experts (SMEs) from Stellantis, Argonne National Laboratory, AVL, and EATON while ensuring compliance with AVTC and industry engineering standards.
- Led subsystem design and simulation activities for battery packs, battery disconnect units (BDUs), and battery modules while managing technical risk, deliverables, and aggressive project timelines.
- Achieved 1st, 2nd, and 4th overall placements across the three-year Battery Workforce Challenge competition among leading North American automotive research universities.
- Contributed to 23 competition awards across technical excellence, battery simulation, DFMEA, documentation, innovation, leadership, and system integration.
R&D Mechanical Engineering Co-op at Longan Vision (2022-01 – 2023-09)
- Led the mechanical design and supported the electrical integration of a wearable IoT carbon monoxide detection device and tactical augmented reality helmet mount.
- Designed and optimized injection-molded components and optical combiner assemblies in SolidWorks Plastics simulation to improve manufacturability and performance.
- Developed CNC-machined test fixtures, rapid prototypes, and validation hardware using FDM and SLA additive manufacturing methods.
- Produced GD&T manufacturing drawings, BOMs, and supplier documentation to support efficient prototype fabrication and assembly.
- Strengthened product reliability by improving DFMEA documentation, implementing root cause analysis (RCA) investigations, and optimizing control plans.
- Successfully completed four major Defense Research and Development Canada (DRDC) contract milestones through cross-functional engineering support.
Graduate TA - Mechanical Engineering Design Elements at McMaster University (2024-01 – 2024-04)
- Delivered tutorials on topics related to design synthesis, fundamental principles of standard design elements, mechanical and fluid power elements, component specification and optimization to 50 3rd year Mechatronics Engineering students at McMaster.
Teaching Assistant (TA) - B. Tech Level I Peer Tutor at McMaster University (2023-01 – 2023-12)
- Assisted over 100 first-year B.Tech students with technical problem-solving and tutoring in C++ programing, electrical engineering fundamentals, statics and mechanics, mathematics, physics, and chemistry.
Education
Master of Applied Science (M.A.Sc) in Mechanical Engineering – McMaster University (2024-01 – 2026-08)
Bachelor of Technology in Automotive & Vehicle Engineering Technology [Co-op] – McMaster University (2019-01 – 2023-12)
Advanced Mechanical Engineering Technology Diploma in Mechanical Engineering Technology – Mohawk College
Business Management Certificate in Business Management – Mohawk College
