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).

Collaborated daily with Tesla studio designers to integrate high volume manufacturing requirements with studio surfaces.

Managed Engineering BOM  for  complex assembly with 84 unique parts; created Request for Quotation (RFQ) packages for production supplier. selection process; calculated "should-costs" to ensure fair supplier quotes; saved ~$450K/year  through negotiations. 

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.

Worked with suppliers in Mexico and China to kick off tooling; analyzed DFM reports, validated Tolerance Stack-up Analyses and supervised high volume ramp overseas and address quality concerns.

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. 

Consolidated parts aggressively to reduce part count from 9 to 1.

Used dimensionless numbers heuristic to calculate optimal cupholder retainer geometry.

Iterated on 10 different resins before developing a custom thermoset resin that met compression set requirements

Achieved a strong balance between industrial design intent, human factors, and engineering requirements

Continuous improvement project of a complex ~50-part mechanical assembly

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

Redesigned the air vents steering mechanism from the ground up for performance gain.

Improved steering of motorized dash air vents by 20% while staying cost and mass neutral.

Maintained complete freedom of airflow directionality using only 2 motors.

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

Design was adopted to be used on base and premium truck variants

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. 

Created 2D surfaces for design reviews with studio designers to integrate DFM requirements into design; achieved studio buy-off.

Collaborated on-site with suppliers in China and Korea to implement a novel technology which improved the cabin carpet construction 

Results: ~35% mass down, ~$1.50 cost down, and a more premium finish