# Dilen Panchal

> Materials Science & Engineering @ UCI

Location: San Francisco Bay Area, United States
Profile: https://flows.cv/dilen

Materials Science & Engineering student at UC Irvine with hands-on experience across mechanical design, fabrication, and embedded systems.

As a Chassis Engineer on UCI's Formula Sun Grand Prix team, I apply FEA (shell and solid element analysis) to optimize structural performance and reduce weight while maintaining safety margins. On UCI's ASME e-HPC team, I design and manufacture CNC-cut fixtures, 3D-printed enclosures, and machined steel components with a focus on tolerances and manufacturability. Through IEEE's Open Project Space, I am developing an embedded hardware system integrating microcontrollers and sensors from concept to deployment.

Proficient in SolidWorks, Fusion 360, FEA simulation, MATLAB, C++, MIG welding, CNC routing, and manual mill and lathe operations. Actively seeking a summer 2026 internship in mechanical or robotics hardware design.

## Work Experience
### Chassis Engineer @ UCI Solar Car
Jan 2025 – Present | Irvine, California, United States
• Optimized seat angle through experimental testing and structural evaluation, achieving a 20% chassis weight reduction while
preserving stiffness and regulatory compliance.

• Strengthened chassis performance using the FEA methods of shells and solid element analysis to increase the factor of safety
by 25% and reduce von mises stress by about 200 MPa.
• Optimized battery pack placement using hand calculations and SolidWorks simulation to improve CG location and mass
distribution, reducing overall vehicle weight and improving turning radius.

• Repaired damaged suspension arms by grinding out failed weld regions and re-fabricating joints using MIG welding, restoring
structural integrity and returning components to competition-ready condition.

### Statics Engineer @ HPVC UC Irvine
Jan 2025 – Present | Irvine, CA
• Designed and manufactured 20+ CNC-cut components for a redesigned welding fixture, applying Design for Manufacturing
(DFM) principles to improve chassis alignment accuracy and weld consistency.

• Produced 2D manufacturing drawings and performed tolerance stack-up analysis on CNC-cut fixture components, ensuring
dimensional accuracy across mating interfaces and reducing assembly errors.

• Fabricated 5+ electrical housings and steel tubing components via 3D printing, mill, and lathe, maintaining tolerance control
and accurate fitments.

### Motel Employee @ 3A Motel
Jan 2022 – Jan 2025 | San Jose, California, United States
Small motel located outside of downtown San Jose. 

Negotiated deals with difficult customers that often times did not speak English.

Set-up, cleaned rooms, did laundry while also working the front desk.

*Did not work from June 2022 to September 2025

### Barista @ Starbucks
Jan 2023 – Jan 2024 | Sunnyvale, California, United States
Prepared and served a variety of beverages with precision and creativity, consistently meeting or exceeding quality standards, and receiving compliments for latte art and presentation.

Delivered high-quality customer service in a fast-paced environment, processing orders efficiently while maintaining speed, accuracy, and attention to detail

Built strong customer relationships by engaging with diverse clientele, resolving concerns, and creating a
welcoming experience.


## Education
### Bachelor's degree in Materials Engineering
UCI Samueli School of Engineering

### Homestead High School

### Certificate in Manufacturing Engineering Technology/Technician
De Anza College


## Contact & Social
- LinkedIn: https://linkedin.com/in/dilenpanchal

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Source: https://flows.cv/dilen
JSON Resume: https://flows.cv/dilen/resume.json
Last updated: 2026-04-10