Tesla - Sr. Mechanical Design Engineer
Drive Systems May 2015 - Oct 2017
Working at Tesla was an absolute dream job. Looking back today, the amazing team I got to work with, is what I miss most. I fully believe in Tesla’s mission and am convinced the company will succeed in the long-term.
Please note: I am only able to share very limited and mostly public information about my work due to non-disclosure agreements with my previous employer. Please reach out if more specific information on a certain topic are required.
Semi Truck
Led the design of a novel clutch system for higher drive train efficiency
The objective was to de-couple one of the two drive axles from the tires to reduce drag losses
As the only appointed mechanical engineer, I was responsible for all system and part design including the actuation mechanism
Model 3 - The world’s first mass-market EV
Differential
Electric Oil Pump
Rotor Shaft & Cooling System
Differential - Responsible Engineer across all vehicle platforms
Ownership of all systems included: design, test and vendor management responsibility
Finite element structural analysis of all components
Topology optimization of differential housing
Tribology and lubrication analysis and system design
Verification testing in-vehicle and on dynamometer
In-house manufacturing related responsibilities
Electric Oil Pump - Part of three person design team
Initial design was completed in only 2 weeks
Electromechanical system design
Part design: pump gears, shaft, housing, bolted joints
Prototype manufacturing and testing
Pump is cheaper and more efficient than third-party designs
Rotor Shaft/Motor Cooling System - Mechanical Lead Engineer
Development of cooling system based on heat transfer specifications
Layout and design of rotor stack retention and press fit
Design of complicated hollow shaft with integrated oil cooling circuit
Further Contributions
Held design and vendor management responsibility for all gear shafts used in Model 3 gearbox
Contributed to the development and sustainment of 5 motor-inverter-gearbox systems
Electrical bearing discharge protection system for AC induction and permanent magnet primary drive motor
Designed test fixtures with microcontroller based sensor, data acquisition and control systems
Developed prototype fixtures for motor production line capable of producing 500k units/year
Designed prototype and series production components:
Machined parts, plastic injection molding, cast iron, die cast aluminum, sintered metal, stamped, cold/hot forging, laser welding, bevel gears, splines, tribological systems, coatings
Managed 20 individual components during Model 3 production ramp to 500k units/year incl. vendor on-site PPAP
Hired and mentored 3 interns
