Work
Case studies from vehicle body design, production manufacturing, and fixture and process engineering. Some programs are unreleased, so details are generalized where needed.
01Bumper Air-Curtain Duct
A bumper duct that channels air through the fascia to form an air curtain around the wheel and tire — validated in the wind tunnel.
Bumper Rigidity Design Guideline
Standardized design criteria that balance pedestrian-impact compliance against bumper sag — now used by the body design team from day one.
03Rapid Prototyping for Body Design
Using 3D-printed parts to check body panel gaps and build wind tunnel hardware long before production tooling exists.
Cybertruck Manufacturing Cells
Took eight vendor manufacturing cells at Gigafactory Texas from drawing review to installation on a production deadline.
05Rocker Lever Measuring Table
A clamping fixture that holds a 15 L engine rocker lever on a datum so two offset surfaces can be measured quickly and repeatably.
Flywheel Balancer Label Failsafe
A label printing system for 12 L and 15 L flywheel balancers that guarantees exactly one correct label per part.
Robot Sealant Process Fix
Used additive manufacturing to create a new process flow that stopped sealant hardening prematurely on a Fanuc robot cell.