Proven
Engineering Work
A track record of solving demanding mechanical design, CNC CAM programming, sheet metal fabrication, DFM tooling, aerodynamic brake duct cooling, and motorsport telemetry challenges.
DSPro Wash Bucket & Detailing Accessories System
Precision sheet metal product design engineered for commercial detailing applications. Features contoured bucket rim bottle caddies, radial laser-cut grit guards, and modular garage storage racks.
Master Bucket & Detailing System Assembly
Full 3D CAD motion simulation showing the contoured bottle caddy rack, bucket rim hook mating, and Mk2 laser-cut grit guard separation baffle.
Contoured Bucket-Rim Bottle Caddy Rack
Precision formed 0.090″ 5052-H32 aluminum sheet metal caddy engineered to hang securely from commercial 5-gallon wash bucket rims with zero fasteners.
Mk2 Radial Debris Separation Grit Guard
CNC laser-cut circular debris separator with thousands of flow channels designed to isolate abrasive dirt particles at the bottom of the bucket.
Wall-Mounted Chemical Bottle Organizer
Heavy-duty modular garage wall rack featuring precision CNC laser cut bottle slots and formed structural mounting flanges.
Yamaha YZF-R1 MotoSpec Tail & Subframe Assembly
Real on-vehicle fabrication photography demonstrating sheet metal bracket design, precision press brake forming, thermal rectifier packaging, and Carbonin race fairing integration.
FABRICATION PROOF 01Full Assembled Subframe & Tail Geometry
Complete physical assembly on the Yamaha YZF-R1 race chassis, showcasing seamless MotoSpec subframe integration.
FABRICATION PROOF 02Formed Sheet Metal Bracket Detail
Precision 0.125″ aluminum sheet metal extension bracket with 90° air bends, relief notches, and fastener counterbores.
FABRICATION PROOF 03Rectifier & Electronics Cooling Placement
Relocated voltage regulator/rectifier positioned directly into high-velocity under-tail airflow for maximum heat dissipation.
FABRICATION PROOF 04Carbonin Race Fairing Fitment & Alignment
Race tail bodywork seated over custom subframe brackets with zero binding, providing quick-release trackside serviceability.
FABRICATION PROOF 05Under-Seat Component Packaging
Compact packaging of wiring harness, battery tie-down, and ECU mounting tabs with high vibration resistance.
FABRICATION PROOF 06Rear Profile & Structural Rigidity
Completed rear subframe profile providing high torsional stiffness under rider weight shifting and aerodynamic downforce.
Project Deliverables Gallery
Sheet Metal & DetailingDSPro Wash Bucket & Detailing Accessories System
Precision sheet metal detailing system including contoured bucket bottle rack caddy, Mk2 laser-cut debris separation grit guard, and wall-mounted chemical organizers engineered for rapid CNC laser and press brake fabrication.
Laser Cutting & DFMDSPro Mk2 Precision Debris Baffle & Grit Guard
Multi-radial debris separation grit guard with over 27,000 laser-cut flow channels designed to trap heavy abrasive particulates below the wash mitt boundary layer.
Aerodynamics & DFAMDucati Panigale V4 Aerodynamic Brake Cooling Cowl
Autodesk Inventor multi-body CAD assembly of an aerodynamic brake cooling duct and rotor cowl for the Ducati Panigale V4 superbike, channeling ambient airflow across 330mm Brembo racing calipers to eliminate brake fade.
Race Chassis & Sheet MetalYamaha YZF-R1 MotoSpec Tail & Subframe Assembly
Custom structural sheet metal bracketry and tail extension hardware integrating Carbonin race bodywork onto a MotoSpec Yamaha YZF-R1 subframe with precision rectifier relocation and electronics packaging.
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.
Sheet Metal FabricationR1 Rectifier & ECU Relocation Bracket Assembly
Close-up of fabricated 0.125″ aluminum sheet metal bracketry positioning the high-heat voltage rectifier directly into under-tail airflow while dampening chassis vibration.
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.
Motorsports IntegrationCarbonin Race Tail Fairing & Subframe Integration
Final assembly alignment of lightweight Carbonin fiberglass/carbon race fairing over the custom MotoSpec tail extension brackets with zero bodywork stress.
Technical Problem → Solution Breakdowns
CLX 4020 Rugged Industrial Enclosure
Client: Confidential Defense & Marine Robotics ClientPackage sensitive high-frequency computing electronics into a sealed, vibration-isolated rugged chassis rated for marine and tactical field deployment under extreme environmental shock.
Engineered an IP67-sealed modular enclosure in Autodesk Inventor with integrated wire routing, thermal heat sink ribs, and multi-axis CNC billet 6061-T6 machining strategies.
- ✓Parametric multi-part assembly (.IAM) with dynamic clearance envelopes
- ✓Complete 3-Operation CNC CAM toolpath setup sheets (Adaptive Roughing & Flow finishing)
- ✓O-ring seal channel & IP67 environmental pressure boundary engineering
- ✓Comprehensive DFM review eliminating secondary manual deburring operations
Yamaha YZF-R1 Racing Dash Mount
Client: Motorsports & Superbike Cockpit IntegrationMount an advanced I2M Chrome Pro 2 racing telemetry dash onto a 200hp superbike cockpit under intense high-frequency engine vibration without adding excess weight or blocking steering lock.
Modeled an organic billet bracket in Autodesk Inventor, programmed 2-operation CNC toolpaths (Adaptive Roughing, Flow finishing, 3D chamfering), and validated rider line-of-sight via additive prototyping.
- ✓Parametric 3D CAD modeling with weight-relief pockets and vibration damping
- ✓Multi-Op CNC CAM toolpaths with constant tool engagement angle
- ✓Comprehensive G-code setup sheets for CNC Program 1501 & 1502
- ✓Functional 3D printed fitment validation prior to metal cutting
Yamaha YZF-R1 MotoSpec Tail & Subframe Assembly
Client: Motorsports Racing & Superbike IntegrationIntegrate Carbonin carbon-fiber race bodywork onto a specialized MotoSpec racing subframe while relocating high-heat electrical components (voltage rectifier/regulator) into clean cooling airflow without chassis interference.
Designed parametric sheet metal brackets in Autodesk Inventor with calculated bend deductions (K-factor 0.44), generated 1:1 DXF cut profiles for CNC laser cutting, and verified physical fitment and wiring harness clearance on the assembled race bike.
- ✓Parametric Sheet Metal Modeling: Multi-part subframe bracket suite with exact bend allowances
- ✓Manufacturing Drawing Set: 2D production drawings with bend angles, relief notches, and flat pattern DXFs
- ✓Electrical Component Thermal Packaging: Repositioned voltage rectifier into clean under-tail airflow
- ✓Complete Physical Assembly & Verification: Assembled and tested on race bike with Carbonin fairing alignment
DSPro Wash Bucket & Detailing Accessories System
Client: DSPro / RevAuto Detailing AccessoriesDetailing chemical bottles and wash tools tip over or fail in harsh wash environments. Needed a rigid, universal bucket-mounted caddy and debris filtration system with zero weld requirements and flat-pack manufacturing efficiency.
Developed parametric sheet metal CAD models in SolidWorks with precise bend deductions (K-factor 0.44), generated 1:1 DXF flat pattern cut profiles, and integrated contoured flange hooks that lock securely onto standard 5-gallon bucket lip geometry.
- ✓Parametric Sheet Metal CAD Modeling: Multi-piece ecosystem including bucket bottle rack, Mk2 grit guard, and wall bottle rack
- ✓1:1 DXF Flat Patterns: Production-ready CNC fiber laser cut packages with kerf compensation
- ✓2D Engineering Drawing Sets: Dimensioned fabrication drawings with bend tables and inspection tolerances
- ✓Dynamic Video & 3D Motion Analysis: Multi-part assembly animation and exploded kinematic motion clips
Ducati Panigale V4 Aerodynamic Brake Cooling Cowl
Client: Superbike Aerodynamics & Thermal ManagementDuct ambient ram air across high-heat Brembo racing calipers and 330mm rotors at 180+ mph track speeds without disrupting aerodynamic downforce or making contact during full fork compression and steering lock.
Modeled organic aerodynamic duct geometry in Autodesk Inventor, incorporating NACA-profile inlet funnels, caliper standoff clearances, and structural reinforcement ribs designed for carbon-infused SLS additive manufacturing.
- ✓Master Assembly (.IAM): Multi-body assembly including caliper mount, 330mm rotor, and cowl ducting
- ✓Aerodynamic Ram Air Funnel: Internal velocity ramps accelerate air directly onto the brake pad interface
- ✓Dynamic Clearance Verification: Validated steering sweep and suspension stroke without fender interference
- ✓Carbon-Infused SLS Manufacturing: 68g lightweight monolithic structure with high heat deflection (HDT > 180°C)
Legit Design Modular Interface Adapter
Client: Legit DesignRapidly iterate an industrial multi-plate component assembly to eliminate flexure under dynamic load while maintaining tight assembly clearances.
Conducted a 4-stage DFM revision cycle (V1 -> V2 -> V3 -> V4) with high-resolution SLA prototyping, wall-thickness structural webbing, and localized fastener counterbore reinforcement.
- ✓4-Stage CAD Revision Progression: Complete engineering record tracking V1 -> V2 -> V3 -> V4 optimizations
- ✓DFM Wall Thickness Analysis: Eliminated localized stress risers and ensured uniform resin cure shrinkage
- ✓Fastener Counterbore Reinforcement: Webbed boss structure designed to handle high clamp loads
- ✓Complete Export Package: Native Inventor, SolidWorks SLDPRT, and neutral STEP/STL exchange models
Track Engineer — Telemetry SaaS Platform
Client: Internal Product / Corner IQAutomate motorsport telemetry analysis for motorcycle and sports car track drivers without requiring expensive $1,500+ proprietary Windows software suites.
Architected an offline-capable, browser-based telemetry app that ingests 100Hz CSV data from RaceBox and AiM Solo hardware, computes cornering G-force and lean dynamics, and generates actionable AI coaching insights.
- ✓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 Race Door Pull Assembly
Client: Driveway Labs Motorsport EngineeringOEM Toyota Supra door latches are heavy and prone to failure when modified for competition race doors. Needed a direct bolt-on motorsport release assembly with precise door cavity alignment.
Reverse engineered the OEM door cavity via optical 3D scanning; created high-strength 3D printed PA-CF nylon structural inserts, 3K twill autoclave carbon fiber faceplates, flush fastener bushings, and high-strength pull straps.
- ✓High-resolution 3D optical scanning & point cloud reconstruction
- ✓Functional PA-CF additive structural inserts with mounting bosses
- ✓Autoclave carbon fiber faceplates with integrated pull strap slot
- ✓Direct track-tested fitment across racing chassis
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