Mechanial Design Engineer at Tesla enabling cost and mass savings for the leading EV manufacturer in the world.
Model Y Rear Halfshaft
One of my main projects on the Chassis, Vehicle Engineering team was to eliminate a machining step on the redesigned 2024 Model Y rear halfshafts in order to reduce cycle time and cost. I was responsible for executing the design change, confirming mass and torsional stiffness changes with stakeholders, and verifying layout changes in the dynamic suspension model, and collaborating with suppliers to implement the VAVE.
Cybertruck Knuckle
My final intern project was to prototype and test different mud ingress and egress paths on the Cybertruck knuckle to prevent mud wade failures. I designed different knuckle geometries, 3D-printed knuckle prototypes, built and planned a bench-level test to simulate a mud wade, and performed tests to determine the best-performing design to present to leadership.
Cybertruck Wheel Speed Sensors
I helped perform a Root Cause Analysis on the Cybertruck Wheel Speed Sensors to understand a recurring installation failure. This required non-linear FEA to determine how associates were applying pressure and torque to the sensor during the install that caused them to snap. I also worked alongside the vendor to suggest and validate design changes, such as adding stiffeners, to strengthen the plastic overmold and increase yield margins to prevent installation failures.
