Leading and building the product development validation team for Battery and Low Voltage Systems.

• Test design of: Mass production reliability campaign, battery safety, vehicle level accelerated durability studies.

• Onsight support of contract manufacturer C sample builds, assembly process steps, end of line procedures – data analysis, and quality control.

• Failure analysis & teardowns to root cause critical failures for production ramp.

Building and testing prototype battery packs for light electric vehicles as part of a small agile team.

• Validation and verification of B sample battery systems, HMI, lighting, and other low voltage systems with a focus on battery safety / passive propagation resistance.

• End to end ownership of internal and contract manufacturer DVP planning and execution. (Reliability, Durability, Regulatory, Safety, Performance Verification)

Engineering Consultant focused on ADAS systems and Electric Vehicle Battery packs, supporting product development, product evaluation, product analysis / failure analysis, and litigation.

• Forward Collision Warning (FCW) and Automatic Emergency Breaking (AEB) system performance and analysis, utilizing AB Dynamics guided robotic platforms, including nonstandard targets and scenarios, to support expert witness litigation, and research.

• Failure investigations and root cause analysis of Electric Vehicle battery packs in recall related matters. Including reviewing design documentation, manufacturing information, incident information, design and process validation testing for recall related thermal events. Presentation of findings at the C-suite and director level.

• Evaluated the safety performance of electric vehicle batteries through customized electrical and mechanical abuse testing. Evaluations included post abuse teardowns to evaluate component level performance of over 60 battery packs of various design and origin.

• Assisted with failure investigations of electrical and mechanical consumer projects.

• Developed and operated robotic systems to reliably control vehicle dynamics for a variety of scenarios, including throttle control systems for emissions evaluation, and utilizing robot-controlled vehicles to perform crash tests with and without emergency maneuvers.

16-month technical internship, designing, building, and testing a 130 kg marine gyroscope stabilizer to reduce boat roll by 65%.

As the only employee assigned this project, I was responsible for planning, designing, and building a prototype marine gyroscopic stabilizer for a 21’5” power boat to reduce boat roll due to waves. The result was a gyroscopic stabilizer prototype with 580 Nms of angular momentum that produced up to 2000 Nm of stabilizing torque controlled via roll angle inputs from an IMU.

I reviewed the rotational dynamics behind gyroscopic motion and developed a control algorithm simulated in MATLAB. I tested this algorithm on a small-scale boat that used puck sized gyroscopes controlled via servo motors, achieving roll reductions of 70%. I presented my findings to the Director of Engineering who tasked me with creating a mechanical design for a full-scale system.

Though a combination of collaborating with company experts and with self study I was able to develop the skills necessary to complete the mechanical design in PTC Creo that included: a 70kg flywheel that spins at 4000 RPM, a 1500W brushless electric motor, 2 hydraulic actuators, 13 structural components, and 53 fasteners.

Throughout this process I had weekly communication meetings with my supervisor and held several design reviews with a panel of engineers to improve and validate the design. This culminated in a formal presentation to the Director of Engineering and the Senor VP of the plant where I acquired $15,000 in funding for the prototype.