Staff Mechanical Engineer, Power Electronics · Jan 2014 — Jun 2022
Tesla
Nine years of charger and DC/DC hardware at the highest volumes in the industry — where architecture decisions are cost decisions, and a cent is a program.
Onboard chargers & DC/DC
Mechanical lead for every generation of onboard charger through Cybertruck, plus DC/DC converters.
Deep dive →
Module architecture & variant reduction
Four investigations into how far one part number could stretch across platforms — and the cost-down programme that came out of it.
Deep dive →
Planar magnetics integration
Six magnetic components absorbed into the PCB, and the thermal work that made it survivable.
Deep dive →
Patented press-fit interconnect
A dual-eyelet press-fit pin replacing screws for PCB-to-heatsink attachment.
Deep dive →
Semi HV-DCDC
1000 V to 400 V converter for Semi thermal and air compressors, from CAD to Gigafactory Buffalo.
Deep dive →
Enclosure sealing & structural FEA
Bolt spacing for seal compression, and lift-ear safety factors for manufacturing handling.
Deep dive →