Cybertruck

Designed an ~80-part Center Console from initial concept to mass production.

Balanced studio design intent with engineering requirements (safety, cost, mass, ergonomics, quality, sustainability and craftsmanship).

Assigned datum and attachment strategies for every part on the Console; partnered with supplier to design fixtures and create CMM point cloud for Statistical Process Control.

Collaborated with cross-functional teams to invent an industry-first cup holder

Mapped Finite Element Analysis (FEA) results to physical prototypes to speed up prototyping by 10x. 

Leveraged Python and computer vision to enhance vane control mechanism and reduce hysteresis.  

Improved steering of motorized dash air vents and reduced noise and part count

Co-developed a novel yacht floor architecture that absorbed large Body in White (BIW) tolerance variations during assembly while maintaining sub-3mm gap and flush conditions at worst case tolerance

Collaborated with power electronics team to integrate a wireless charging unit into the phone dock  tray 

Solved phone overheating/ disconnecting issue by balancing susbtrate thickness using FEA studies.

Leveraged creative injection molding tool design to consolidate part count from 8 parts to 2; reduced assembly cycle time by 30s.