David Hill

Mechanical engineer with 18 years’ experience developing advanced automotive test systems, real-time controls, instrumentation and prototype vehicle integration. Experienced in integrating hardware, software and control systems for complex engineering programmes, including real-time powertrain development, prototype vehicle simulation, ECU calibration, CAN communications, hydraulic test systems, vibration analysis and engineering automation.

Senior Test and Development Engineer at Caudwell Marine (2025-08 – Present)

Responsible for the development, integration, commissioning and validation of advanced electro-hydraulic test systems for marine powertrain development, combining PLC control, Python supervisory software, CAN communications, instrumentation and hydraulic systems.

• Coordinate test planning, instrumentation, validation and engineering reporting across multidisciplinary teams to support product development and design verification.
• Perform vibration and NVH investigations using DewesoftX and MATLAB, including FFT, order tracking and modal testing to identify resonances and support root -cause investigation.
• Plan and execute durability, reliability, performance and functional validation programmes.
• Produce engineering reports to support design decisions, verification and product sign-off.
• Lead the commissioning of a closed-loop electro-hydraulic steering test rig integrating PLC control, CAN communications, hydraulic actuation and Python supervisory software for automated steering system validation.

Emissions Laboratory Manager at Lotus Cars (2024-08 – 2025-08)

Managed the technical capability of the emissions development facility supporting prototype development, certification and production compliance.

• Managing laboratory capability, calibration and resource planning
• Supporting prototype vehicle development and Conformity of Production testing.
• Developing laboratory processes, equipment capability and engineering procedures.
• Leading delivery of legally required emissions certification programmes.
• Commissioned and configured an ABB DCS800 DC drive following replacement of a failed dynamometer drive system, restoring dynamometer operation ahead of specialist refurbishment and final validation.

Senior Automotive Research Engineer at Cambustion (2011-11 – 2024-08)

Worked within an advanced consultancy developing real-time powertrain development systems for prototype OEM programmes. Developed and operated integrated engine development environments combining physical engines, virtual vehicle models and prototype ECUs to accelerate calibration and aftertreatment development before complete prototype vehicles were available.

• Development and operation of real-time engine development systems integrating physical engines with virtual vehicle models, driver models and simulated vehicle subsystems.
• Integration of prototype ECUs with simulated vehicle environments through CAN communications, signal simulation and real-time plant modelling.
• ECU calibration and control strategy development with ETAS INCA and ATI Vision.
• Development of gasoline, hybrid and diesel aftertreatment systems including catalysts, gasoline particulate filters (GPF), diesel emissions systems and on-board diagnostics (OBD).
• FPGA-based measurement and deterministic data acquisition systems.
• Customer facing consultancy, technical reporting and presentation of development results to OEM engineering teams.

Engine Test Engineer at Johnson Matthey (2007-03 – 2011-10)

• Planned and executed transient engine test programmes for development of diesel emissions control technologies.
• Rigged, instrumented and operated gasoline and diesel engine test facilities for catalyst ageing, evaluation and development.
• Processed and analysed engineering test data to support product development.

HND Work Placement at Triple Eight Race Engineering (2003-06 – 2003-07)

• Assisted fabrication and composite departments supporting preparation and repair of BTCC race vehicles.
• Manufactured composite bodywork components using fibreglass and E-glass construction techniques.
• Stripped, inspected and rebuilt transmission sub-assemblies and racing gearboxes to support vehicle preparation.

MEng in Automotive Engineering – University of Hertfordshire (2004-09 – 2007-05)

BTEC HND in Automotive Engineering – Swansea Institute of Higher Education (2002-09 – 2004-07)

BTEC OND in Mechanical Engineering – North Herts College (2000-09 – 2002-07)