Engineering Portfolio
Check out my personal, FSAE, a projects
One of my proudest engineering achievements was developing a comprehensive data-driven model for a residential solar panel installation company used to predict solar project duration with precision. By integrating multiple datasets, designing a custom optimization routine using differential evolution, and refining the results through curve fitting, I managed to capture the complex interplay between panel quantity, tilt, drive time, and other key factors. This not only elevated our ability to create schedules more reliably but also showcased the usefulness of data driven algorithms in solving real-world engineering challenges.
Manufacturing
This year, I had the opportunity to work alongside the Manufacturing Lead for FSAE to machine several components using the HAAS lathe, manual lathe, and PROTO-TRAK CNC mill in Lacy Hall. My three most notable projects involved turning 6061 aluminum hex bars to a precise diameter within 0.010” for torsion testing in a mechanical lab, cutting and machining steel pipes for the A-arms and push/pull rods in UVA’s Formula SAE EV suspension, and drilling and tapping push/pull rods to accommodate left- and right-handed threads for Heims.
The aluminum hex bars required a precise center diameter to ensure accurate torsion test results. However, machining them on the HAAS lathe introduced a challenge—bowing in the middle due to back pressure from the tailstock, which caused slight variations in the final diameter along the length of the part. Overcoming this issue required adjustments to machining parameters and setup to minimize deformation while maintaining accuracy.
The A-arms and push/pull rods were critical suspension components for UVA’s Formula SAE EV car. The process began with cutting 0.5” steel pipe to approximate length, followed by turning down each end on the lathe to achieve an accurate final length within 0.010” before welding. After welding, the push and pull rods were separated, then drilled and tapped on the lathe to cut left- and right-handed threads for heims. Finally, heims were threaded onto each rod to complete the assembly.
Powertrain Responsibilities
As a powertrain member, one of my responsibilities was making sure the IC car would run before big events. I was deeply involved in the repair and maintenance of our internal combustion car to ensure it was competition ready for driver training days, public events, and even competitions. Along with the powertrain lead, I disassembled and set the timing on the R6 engine in the Formula SAE IC car. Additionally, I led multiple clutch rebuilds due to an issue caused at a competition that later resurfaced in a driving day. Due to the work I put into the IC car, we were able to hold multiple driving days in order to prepare for upcoming competitions by giving our drivers as much lap time as possible. This experience not only sharpened my technical skills but also taught me the value of precision and working with a team in preparation for high stress testing and aggressive competition driving.
