Proven
Engineering Work
A track record of solving demanding mechanical design, CNC CAM programming, DFM tooling, industrial automation enclosures, and high-frequency motorsport telemetry challenges.
Real Hardware & Deliverables
Reverse EngineeringMKV Toyota Supra GT Door Pull Latch Assembly
Reverse engineering and custom fabrication of lightweight motorsport GT door pull latches for the MKV Toyota Supra utilizing functional 3D printed carbon-nylon inserts, CNC machined bezels, and autoclave carbon fiber faceplates.
Track Engineer AppTrack Engineer — Session Insights & Telemetry UI
Real in-app screenshot of Track Engineer showing high-speed GPS velocity (151.8 mph), lap consistency metrics, left/right max lean angle, peak braking/acceleration G-force, and lap time sector charts.
DFM & Tooling DesignProject Apex-9 // Enclosure DFM & Mold Tooling
Comprehensive Design for Manufacturing (DFM) review evaluating draft angles, parting line shut-offs, core/cavity pulls, and wall thickness uniformity for heavy-duty electronic enclosures under NDA.
Track Engineer AppTrack Engineer — Tire Pressures & Session Logger
In-app screenshot showing pre- and post-session cold/hot tire pressure tracking, track temperature notes, and multi-session historical data storage.
Reverse EngineeringMKV Supra Carbon Fiber Interior & Door Integration
On-vehicle track testing and fitment of the custom carbon fiber door latch assembly on the MKV Toyota Supra race chassis.
DFM & Tooling DesignProject Apex-9 // Mold Cross-Section & Wall Analysis
Detailed internal cross-sectional CAD inspection ensuring uniform resin flow, zero sink marks, and optimal structural rib placement for ruggedized tactical device enclosures.
Engineering Breakdown
CLX 4020 Automated Industrial Machine Enclosure
Client / Partner: Cincinnati Inc. & MQ AutomationDesign an operator-safe, debris-containing modular enclosure for a massive fiber laser cutting system (6.3m x 4.1m x 2.1m) requiring rapid field assembly, sliding operator door interlocks, and standardized sub-assemblies.
Engineered an extruded aluminum framework (Bosch Rexroth 40x80, 40x40, and 30x30) with custom 6061-T6 CNC machined base plates, standardized miter connectors, and a 17-sheet ASME Y14.5-2009 drawing package.
- ✓Complete Top-Level CAD Assembly (.SLDASM, .STEP) across 4 master sub-frames
- ✓17-Sheet ASME Y14.5-2009 GD&T drawing set with cut lists & schematics
- ✓Automated 70+ line item Bill of Materials (BOM) covering extrusion finishing & hardware
- ✓Custom 6061-T6 machined base mounting plates, slide blocks, and latch plates
Yamaha YZF-R1 Racing Telemetry Dashboard Mount
Client / Partner: I2M Chrome Pro 2 Motorsports Cockpit IntegrationMount an advanced I2M Chrome Pro 2 racing telemetry dash to a 200hp superbike cockpit under intense high-frequency engine vibration and 180+ mph aerodynamic loads without adding excess weight.
Developed an organic billet bracket in Autodesk Inventor, programmed 2-operation CNC toolpaths (Adaptive Roughing, Flow finishing), and validated fitment via 3D printing before cutting metal.
- ✓Parametric 3D CAD Modeling: Optimized bracket geometry for weight reduction and high-G stiffness
- ✓Multi-Op CNC CAM Toolpaths: 2-op strategy with full G-code generation (Prog 1501 & 1502.nc)
- ✓Comprehensive Setup Documentation: WCS offsets, tool libraries, speeds/feeds, and cycle times
- ✓Functional Rapid Prototyping: Additive SLS (3MF / STL) fitment validation trackside
Custom Multi-Plate Component Assembly
Client / Partner: Legit DesignRe-engineer mating components across multiple rapid revision cycles to eliminate internal stress concentrations and optimize SLA resin printability without warping.
Evaluated dimensional clearances across 4 iterations (V1 to V4), transitioning from prototype resin to end-use nylon-like tough resin with reinforced internal radii and optimized drain holes.
- ✓Iterative DFM Optimization: Evolved design from V1 to V4 to reduce stress concentrations
- ✓Tolerance & Fitment Studies: 3D CAD assembly comparison identifying dimensional clearance improvements
- ✓Additive Material Specs: SLA Nylon-Like Tough Resin (25-micron layer resolution, 100% infill)
- ✓Multi-Format CAD Deliverables: Autodesk Inventor (.iam, .ipt), SolidWorks (.SLDASM), and STEP models
Track Engineer — Telemetry & AI Coaching Platform
Client / Partner: Corner IQ / KBD Proprietary SoftwareRiders and race engineers lack an intuitive, hardware-agnostic platform to visualize 100Hz telemetry data, satellite cornering lines, and real-time coaching debriefs in pit lane.
Architected a responsive digital race engineering web application supporting 45+ satellite track maps, direct CSV telemetry ingestion (RaceBox and AiM Solo), overhead friction circles, and an AI Race Engineer that breaks down every session turn by turn.
- ✓45+ high-resolution satellite track maps with turn placards
- ✓Hardware-agnostic 100Hz CSV ingestion & traction circle algorithms
- ✓Turn-by-turn AI coaching & lap time reduction action plans
- ✓Club & organization live leaderboards (OMRL, ASRA)
MKV Toyota Supra GT Door Pull Latch & Carbon Aero
Client / Partner: Driveway LabsOEM Toyota Supra door latches are heavy and prone to failure when modified for competition race doors. Needed a direct bolt-on motorsport release assembly.
Reverse engineered the OEM door cavity via optical 3D scanning; created high-strength 3D printed PA-CF nylon inserts, CNC machined billet trim rings, and lightweight autoclave carbon fiber faceplates with integrated pull straps.
- ✓High-resolution 3D optical scanning & point cloud reconstruction
- ✓Functional PA-CF additive structural inserts
- ✓Autoclave carbon fiber faceplates with integrated pull strap
- ✓Direct track-tested fitment across racing chassis
Aerospace & Marine Autonomy Whitepapers
Authoritative technical briefs highlighting our payload integration, DFM analysis, and autonomous unmanned marine vessel engineering.
Modular USV Catamaran Operations for Tactical Marine Autonomy
Comprehensive technical overview of autonomous unmanned surface vessel (USV) catamaran architectures: hydrodynamic drag reduction, modular sensor payload integration, ruggedized waterproofing, and low-latency command telemetry.
Engineered Aerospace Systems & Payload DFM for First Response
Engineering analysis covering airborne sensor payload integration, rapid-deployment structural mounts, lightweight carbon-fiber composite layups, and vibration-damping mechanical enclosures for aerospace missions.
Have a mechanical, CAD, or tooling challenge?
We provide rapid engineering assessments, DFM reviews, and fixed-scope proposals tailored to your timeline.