Work
Experience
Sep 2022 - Jan 2023
Megapack Design Engineering Intern - Tesla
- Owned design/construction of full-scale PP3 test buck to validate thermal system. Testing resulted in improvements with radiator and manifold design, system performance understanding, as well as service strategy improvements.
- Owned design for injection molded high-pressure coolant plug. Conducted FEA, DFM/DFA, and tolerance stack analysis. Worked with suppliers to iterate production tooling and validate part readiness for volume production.
- Investigated battery cold-plate leak risk due to denting. Characterized deformation/stress relationship, analyzed dent coupons with CT scanner and optical metrology, and defined max acceptable dent size to ensure 20 year operating lifespan.
- Leak-tested NW37 connectors to characterize o-rings | Prototyped magnet-based megapack HVIL door-open sensor | Designed/built sight glass addition for PP3 refrigerant system for visual analysis | Designed multiple sheet metal brackets for PP3.
Jan 2023 - Aug 2023
Energy Thermals - Design Engineering Intern - Tesla
- Owned prototype design for significantly simpler and lower cost next-gen megapack thermal system. Over 5+ months designed/built CNC milled aluminum plate, with interfaces for 40+ integrated thermal components, and internal 3D channel routing for refrigerant and coolant flow. Considered heat transfer and pressure drop for channel design to achieve desired thermal/performance results.
- Manufactured using undercut features, stir welded channel caps (FEA informed design), and pass throughs for 3D channels.
- Designed 5x refrigerant lines with integrated sensors, and an 80-20 frame for mounting all components. Created 30+ drawings for all parts, considering tolerance needs and corresponding datuming schemes. Worked with suppliers to manufacture all components.
- Owned design/build of megapack test buck to trial noise reduction solutions and unlock $100M+ of revenue.
- Worked with NVH team to understand noise profile, and design/construct baffles, louvers, vibration dampeners, and insulation. Sourced components, coordinated assembly, and delivered completed buck to NVH lab for testing.

May 2022 - Aug 2022
Mechanical Engineering R&D Intern - FormFactor
- Designed & manufactured test coupon to measure the thermal resistance properties of micrometer scale probes with IR camera.
- Designed PCB with AutoCad and used it to measure the electrical resistance of micrometer scale probes with 4-wire method.
Nov 2018 - Jun 2020
Drone Mechanical Design Intern - AutoModality
- Led hardware design project to create a compact and versatile drone for use in autonomous inspections of tight spaces.
- Drafted, machined, assembled, and iterated design. Learned carbon fiber layup to construct frame, & high strength 3D printing.
- Final drone was displayed at Nevada’s globally recognized Consumer Electronics Show in Jan 2020 and integrated into AutoModality’s future commercial projects.
Sep 2018 - Mar 2020
Aerial Drone Photogrammetry Intern - Guardian Airwaves
- Initiated and led a project to create high resolution 3D terrain maps with drones through aerial Photogrammetry.
- Terrain models used as a foundation for extreme disaster simulations and immersive virtual reality firefighter training products.


Jan 2017 - Sep 2019
Owner, Organizer, and Lead Instructor - Drone Building Camps
- Founded my own drone building summer camp for kids.
- Created a detailed curriculum, designed a fully functional website, and coordinated partnerships with overseas parts manufacturers. Worked on marketing and advertising, rented out a local maker space, and ensured legal security through waivers and insurance.
- Over 3 years, single handedly taught 50+ students in 3-5 day summer camps and was featured in a local newspaper and radio station.
Skills
& Expertise
Software/Design:
- Solidworks + FEA, AutoCad, Fusion 360, Matlab, Python, GD&T Engineering Drawings
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Prototyping:
- 3D Printing, Carbon Fiber Layup, Laser Cutting (incl. metal laser cutting), Lathe, Manual/CNC Mill, Water Jet,
- Battery Module Design & Optimization (LiPo, LiIon, LiFePO),
- Electronics (motors, controllers, PCB design, soldering, spot welding)
Languages

English: Native Speaker, Fluent

Italian: Native Speaker, Fluent

Spanish: High comprehension, intermediate speaking