Senior Model Design Engineer at Alpine F1 Team (2023-10 – Present)
Quickly integrated with new group and took responsibility for most workflow activities including managing junior engineers and contractors, planning, design, and delivery of wind tunnel (WT) projects
- Improved WT testing accuracy and repeatability by developing improvements for floor edge adjuster mechanisms and successfully implemented them on the WT model and into testing procedures
- Increased reliability of pressure measurement system by developing new captive manifold design
- Improved WT change time & accuracy by developing CFRP reinforced part structure using modal FEA to increase natural frequency & prevent vibration of performance critical floor bargeboards tips
- Performed design reviews of new projects including engineering drawings, & recommended new ideas & concepts for upgrade projects to solve problems and increase capabilities to Lead Engineers
- Improved speed & efficiency of part creation & ECR resolution by implementing CAD structure changes
- Created up to date BOM reference assemblies for WT model as new parts were retained after testing
- Led WT model development of 2025 car floor through launch spec release with limited resources
Aerodynamic Design Engineer at Aston Martin F1 Team (2017-08 – 2023-10)
Spearheaded WT model development as acting senior design engineer in performance-critical floor group - responsible for managing & creating large share of parts & test plans to daily tight timescales
- Designed a wide variety of WT model systems from structures to pressure tap & active suspension systems to complex aerodynamic survey parts & assemblies
- Led design reviews for floor assembly when developing new WT model for next-gen regulation changes
- Routinely issued engineering drawings to challenging deadlines & late requests in WT project needs
- Utilized a variety of manufacturing methods including CNC milling, 3D printing, & composite layup
- Supported, trained, provided mentorship, performed drawing and design reviews for junior engineers
- Coordinated with production, model-build, & others to ensure quality parts ready on schedule for testing
- Set WT test plan documentation with BOM & install instructions, supported in person & out-of-hours
- Rebuilt CAD models with DFX principles, used live links & skeletons to generate new parts quickly & consistently, integrated build supports, clean out features, and jig interfaces to speed production
- Maximized data gathered from WT with new parts to work with laser measurement systems
- Developed standards for wing & floor FEA & correlated to testing to control deflection & vibration
- Created kinematic suspension sweep envelopes & analyzed feasibility of new suspension features
- Enabled larger and faster changes on WT model by developing quick release connectors & assemblies
- Developed flex cycle rig, planned and performed testing of new multi-material flexible 3D print system
- Improved floor WT testing repeatability with floor height check jig and adjusters, reducing variation 50%
Mechanical Design Engineer at Manor Racing F1 Team (2016-08 – 2017-02)
Designed a variety of assemblies for the suspension system
- Designed a variety of assemblies for the suspension system including anti-roll bars, adjustable heave springs, dampers, bumps-stops systems, rear hub, constant velocity joint assembly & more
- Optimized part strength, stiffness, & mass utilizing FEA during initial part design; streamlining workflow with stress analysis group. Taught methods and workflow to peers and engineers in other depts
- Designed torsion spring sets achieving target travels & rates in high temp range, & reduced hysteresis
- Developed new concepts for 2017 wheel-nut/socket system & mocked up utilizing rapid prototyping
- Rapidly designed composite laminates, moulds, & tooling to upgrade 2016 chassis to 2017 regulations
- Thrived in a small team environment where I had the opportunity to tackle problems & make an impact
- Developed street circuit of new Miami GP for early stakeholders using Excel vehicle dynamics sim
Scuderia Ferrari F1 Team - F1 Academy Engineer at Ferrari SPA (2015-11 – 2016-05)
1 of the 6 selected from hundreds of finalists after 3 rounds of interviews, technical tests, & challenges
- Performed lap time simulation analysis using Matlab to select the optimal aero package for races
- Worked in the composite production department learning the process of layup, trimming, & finishing
- Developed an excel statistical model to predict composite BOM needed for suppliers to create parts
Engineer – Underbody Design at Honda R&D Americas (2011-07 – 2014-08)
Responsible for development of vehicle body structures from early concept through to mass production
- Managed over 50 assemblies over development program, production ramp-up, & issued final drawings
- Orchestrated improvements for new side-pole and small overlap crash tests, working closely with crash testing & simulation group to earn 2nd ever IIHS Top Safety Pick+ rating for 2015 Acura TLX
- Supported environmental tests ex. high/low temperature cycle, rough road/NVH, water deluge, assisted in running test plans, inspecting test vehicles, analyzing results, & proposing countermeasures
- Collaborated with many departments to optimize packaging layouts to meet cost & performance targets
- Developed high efficiency front end air intake system for the radiator, AC condenser, & engine bay cooling. Designed new bulkhead cover geometry to prevent water and snow ingress to engine intake
- Performed cost analysis of my parts & assemblies, optimized designs & production methods using DFMA principles to reduce costs and created reports for supplier negotiations to set lower prices
- Ensured high quality parts by inspecting supplier tooling, fixtures, & parts for prototype & test builds
- Oversaw pre-production builds & inspected vehicles during assembly & after testing to identify problems
- Assembled documentation for NHTSA & in-house homologation design reviews for final production GO
- Performed feasibility analysis on several prospective under body cover assemblies and developed parts to improve body rigidity, crash performance, Noise/Vibration/Harshness, & reduce aerodynamic drag
- Worked closely with parts suppliers to ensure part formability, quality, & to reduce costs using a variety of manufacturing methods such as stamping, extrusion, welding, injection moulding, & composites
- Managed several engineering contractors to create CAD & issue drawings for Ridgeline pickup bed
- Volunteered for HR recruitment events for graduates on site & at Formula Student Michigan event
Engineering Co-Op – Information Systems at Honda R&D Americas (2010-05 – 2010-08)
- Evaluated software packages for CAD manikin implementation and created ergonomics standards
