Newark, California | July 2020 - August 2021

Lucid Motors

Mechanical Engineer, HV Mechanical team | Power Electronics & Motorsports

Image

Overview

I worked to improve, design and progress a suite plastic components critical to the power inverter of the production Lucid Air models, taking most from 3D printed prototyes through tooling and PPAP. I also had the unique responsiblity of being the lead Design Responsible Engineer for the mechanical design of the Gen3 Formula E front powertrain inverter. I was able to overhaul the initially tendered design, radically improving power density with package rearchitecture and development of an ultra-dense link capacitor, yielding one of the worlds highest performance inverters of its class.


Some Highlights:

  • Lead DRE for novel 250kW Formula E racing inverter, taken through concept, modeling sourcing and validation, with components spanning IM plastic, formed metal, machined, PCBA, harnesses

  • Overhauled initial tendered design with material efficiency improvements and reshaping of core layout, resulting in 17% weight loss, 61% higher power density, lower part count and simpler serviceability

  • Proactively seek out and collaborate with CMs, Tier 1s and prototype vendors to validate DfM, continuously manage quality and handle deviations for tens of parts with volumes from 00’s to 0000’s

  • Create virtual models for optimisations, conduct tolerance stack-ups, HV-chain safety analyses

  • Write part/system level specifications, DFMEA reports, part/assembly drawings to ASME Y14.5 standard

  • Design assembly processes, custom jigging hardware, WIs/SOPs and servicing routines

  • Define DV plans, physical build/workshop efforts and support technicians through testing and rework