The requirement

A stop-gap converter until the 1000 V compressor design cleared its own reliability concerns, some eight months out. Priority was stated explicitly as time → reliability → cost, in that order — which let the team make fast trade-offs without re-litigating them.

What I owned

The enclosure, supporting busbars, DC filtering PCBA, harnesses and coolant connections. CAD and detailed drawings, supplier engagement for a machined-part build of ten and a cast-part production path, structural and thermal FEA, tolerance stack-up, physical bring-up, and the manufacturing plan for Gigafactory Buffalo.

Build and integration

Design and simulation ran 12 weeks, board bring-up and initial testing 4 weeks, and alpha truck integration 2 weeks.

On the truck

Installed on the alpha truck for integration testing.