Skills

CAD – CATIA V5 and 3DExperience (Solid Modelling, Surfacing, Drafting / Full GD&T Technical Drawing, 3D Functional Tolerancing and Annotation, Linear FEA – Generative Structural Analysis, Kinematics, Associative Vehicle Architecture (AVA) / Knowledgeware / Parametric Modelling), Solidworks, AutoCAD

PLM – TCe (IBM Trained with JLR), Enovia VPM, 3DExperience

Automotive – Body Structures, Interior Trim, Seating, Restraints, Airbags, Exhaust Systems, Ergonomic Studies, A-Class Surface Development, B-Class Surface Engineering

Aerospace – Interior Structures, Monuments

Other Knowledge – BoM Management, Jig and Fixture Design and Manufacturing, DFMEA, DVP, R&D, Automotive Safety Testing, NPI, Part Releases, Production Issue Problem Solving, Microsoft Office Suite, Design Review Presentation, Assembly and Build Analysis and Documentation, Benchmarking (A2Mac1)

Employment History

Feb 2020 - July 2020           

 

VINFAST LLC, Seating and Restraints, Airbag Systems and Steering Wheel Design / Lead Engineer (Supporting), Hanoi, Vietnam

                                   

Blank sheet design through to concept for a 3rd seat row meeting FMVSS standards. Design process included: ergonomics studies for both seating positions, ingress / egress of the occupant, cushion and back seat frame, kinematic analysis and creation to meet stowed and in-use targets, integration into BIW, comfort and master sections released to Pininfarina styling team. Creation of Scope of Requirement (SOR) documentation for mechanisms. Lead Engineer role for restraints, airbags and steering wheels managing supplier meetings, component VP build and production part releases, managing cross-functional meetings with extensive integration into Vehicle Architecture, external Styling, Ergonomics and managing design integration into other function groups.

 

Nov 2019 - Feb 2020           

 

HPL Proto, Show Car / Prototype Vehicle Design Engineer, Coventry, West Midlands, United Kingdom

                                     

Providing Engineering, Design, Production direction for bespoke show cars with inputs from British Luxury Automotive OEM Design Studies. Extensive engagement with shop floor tool makers, fabricators and production technicians as well as in-depth meetings with the customers.  Projects included GRP and CFRP mould and component design of interior and exterior components, machined ABS components, rapid prototype components, ureol tooling board components and moulds and steel welded armatures. Design undertaking in CATIA V5 using surfacing and solid modelling, production and assembly drawings with appropriate tolerancing and release of parts for production. 

 

Aug 2019 - Nov 2019           

 

LEVC (Geely Group), TX5 / VN5 Body Structures and Exteriors Design Engineer, Coventry, West Midlands, United Kingdom

                                     

Lead the release of the VN5 Electric Van Body Structures and Exterior Panels VP Build release and initial build sequence. This included analysing the required build tolerances and creating the relevant part drawings and inputting into manufacturing engineering jigs and fixtures. Supplier interaction to ensure that parts could meet LEVC quality standards and required build tolerances within the programme timing. Assessing all current assembly jigs and fixtures for the TX5 Electric London Taxi and designing new sub-assembly jigs and fixtures to improve quality standards and build takt time.

 

Aug 2018 - Aug 2019           

 

McLaren Automotive, Full Vehicle Prototype Vehicle Design Engineer, Woking, Surrey, United Kingdom

 

Design of components for mule vehicles across various function groups including exteriors, structures and powertrain systems using composite materials, metallic materials and rapid prototype materials. Designed using CATIA V5 and released in SAP with Enovia integration. Ownership of design at both part and assembly level, creating Manufacturing Assemblies to support the prototype build process utilising McLaren standards and knowledge of fastener and manufacturing methods. This involved producing manufacturable designs, analysing using CAE techniques, creating 2D GD&T and 3D FT&A manufacturing drawings. Additionally, I supported the studio in future vehicle development through creating concepts, master sections and hardpoints.

 

Feb 2018 - Aug 2018           

 

Emerald Automotive (Geely Group), TX5 Body Structures Design / Project Engineer, Coventry, West Midlands, United Kingdom

 

Primary Design Engineer for the TX5 Electric London Taxi Cost and Weight Reduction team. Involving identifying cost and weight reduction using VAVE and re-engineering of relevant components. Integrated within the core design team, working alongside manufacturing engineering, supporting supply chain and assessing CAE crash and load case requirements running linear FEA and supported by a dedicated CAE team for complex load cases. Working on a bonded aluminium extruded, cast and sheet metal body structure, I gained a strong awareness for DFM guidelines of these materials and manufacturing processes. Ensuring no changes had ‘knock-on’ affects to other function groups. These components were designed using CATIA V5, released using Enovia and extensive BoM management with business releases to strict programme timings. Designs included part and product level design, ensuring correct fasteners were used and 2D technical drawings were developed as per BS8888. To ensure that these designs were effective and manufacturable, I had to work closely with the manufacturing engineering team as a Project Engineer, ensuring jigs and fixtures were still suitable, parts had the correct tolerance stack-up to prevent any build issues further down the line and reduced takt times to support the ramp-up of the vehicle.

 

Sept 2017 - Feb 2018         

 

Rockwell Collins (BE Aerospace), Bespoke Monuments Design Engineer, Leighton Buzzard, Bedfordshire, United Kingdom

 

Responsible for the creation of advanced 3D engineering designs and appropriate 2D and 3D technical drawings for manufacturing components and fabricated assemblies. Design of parts for machining, extrusions, vacuum formed plastics, sheet metal components and composite pre-impregnated lay-ups for fiberglass components. Cross-functional work with stress engineers to understand if the intended design will conform to extreme load case scenarios. Understanding of design for customer specifications (Airbus and Airlines) as well as an understanding of EASA requirements. Functional, feature and manufacturing feasibility analysis to identify cost down ideas and see them through to manufactured components. BoM Management and release of parts through a tight checking process integrated into TCe to meet tight programme deadlines.

                                                                               

 

Aug 2014 - Aug 2017   

 

Jaguar Land Rover, Apprentice AVA CAD Engineer, Gaydon, Warwickshire, United Kingdom

 

Responsible for the creation of highly innovative, Associative Vehicle Architecture (AVA) Catia V5 and V6 (3DExperience) models for reusability across multiple programmes in Body Engineering – Interiors and Closures. Programme support for model year and new programmes (Range Rover, Range Rover Sport, Jaguar I-Pace, Jaguar E-Pace) and appropriate CAD support. Attended, supported and presented at design reviews with senior management to support design functionality and to demonstrate release and use of AVA models.

 

Sept 2012 - Aug 2014           

 

Alstom Grid, Apprentice CAD Technician / Workshop Technician, Gaydon, Warwickshire, United Kingdom

 

Spent time working in a production environment and on-site working to relevant National Grid Health and Safety Regulations. Responsible for the creation of technical layout drawings of National Grid Substations 400kV, 275kV, 132kV using AutoCAD. Helped to implement parametric modelling and 3D modelling methods with both Autodesk Revit and AutoCAD.

Qualifications

Sept 2017 - July 2019 - Aston University

 

Bachelors of Engineering (BEng) in Applied Engineering – First-Class Honours, 76.15% (Awarded Horizon’s Bursary by the Institute of Engineering and Technology)

Sept 2014 - July 2016 - Coventry University

Foundation Degree in Engineering (FdEng) – Merit

Sept 2012 - July 2014 - Stafford College

BTEC Level 3 Diploma in Engineering – Distinction*Distinction*

Sept 2012 - July 2016 - Stafford College / Warwickshire College

NVQ Level 2 Automotive Mechanics, Electrical Instillation, Fitting, Turning, CNC Programming and Machining, CAD and CAE

Luke T Seal Engineering