Design | Analysis | Realization

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Alex Vazquez

About Me

Hello! I'm Alex. I'm a graduating senior at the University of Florida studying mechanical engineering. Check out some of my experience below!

Data Analysis

Parsed, visualized, and presented insights from complex test data.

Product Design

Designed parts and assemblies for ergonomics, structural integrity, and real-world assembly.

Process Development

Streamlined part manufacturing using automation and continuous improvement methodologies.

Project Management

Led large cross-functional scope projects from proposal through execution.

Test Development

Designed physical test setups and defined metrics to validate part or system reliability.

Design for Manufacturing (DFM)

Optimized part materials and geometries to ensure scalable and cost-effective production.

Process Failure Mode and Effects Analysis (PFMEA)

Identified and mitigated potential process failures before they impacted production.

Finite Element Analysis (FEA)

Validated solid mechanics and heat transfer behaviors under various load conditions.

Composite Manufacturing

Designed and manufactured complex molded parts and structures from composite materials such as carbon fiber and kevlar.

Laser Welding & Cutting

Welded battery interconnects and cut thin materials with high precision.

Geometric Dimensioning & Tolerancing (GD&T)

Created part drawings for manufacturing with precise dimensions and tolerances.

Fixturing Design

Designed and implemented custom fixtures to streamline various part manufacturing processes.

Computer Aided Design (CAD)
  • SolidWorks
  • Autodesk Fusion
  • Autodesk AutoCAD
  • CATIA
Programming Languages
  • Python
  • MATLAB
  • SQL
  • CNC G-code
  • Arduino
  • ROS2
Data Visualization Tools
  • Microsoft Excel
  • Databricks
  • Hex
  • MATLAB
Project Management
  • JIRA
  • Confluence
Finite Element Analysis (FEA)
  • SolidWorks
  • Ansys
  • Abaqus
Computational Fluid Dynamics (CFD)
  • SolidWorks
  • Star-CCM+
Graphic Design
  • Adobe Photoshop
  • Adobe Illustrator

Portfolio

Experience & Projects

Battery Interconnect Fatigue Testing

Spearheaded the fatigue testing regiment used to validate battery module current collector to cell interconnect weld reliability.

  • Designed coupons and test setup, ran both quasi-static and fatigue tests, and compared empirical results against CAE modeled requirements to ensure long-term durability.
  • Collaborated with product development engineers to integrate test findings into design improvements.
  • Broke down the improvements and significant findings to leadership and documented the results and methodology for future reference.

Weld Clamp Design

Designed and commissioned a set of retrofit weld clamps to replicate production machine clamping footprints on a patent-pending weld mask used on the module pilot line.

  • Used a drafted interior oriface to assist the vision targeting system in placing precise welds.
  • Recalibrated pilot line welding vision and laser parameters to adjust for change in footprint shape prior to validation build production.
  • Designed to be injection-molded from PEEK material due to strong thermal and rigid properties.

Module Busbar Heat Stake Rework Testing

Conducted comparison trials for the rework adhesive used to adhere busbars to the module frame.

  • Determined most efficient volume and distribution of adhesive to bond busbars to frames.
  • Strength tested adhesive rework setups and compared to heat stakes of varying heights and staking pressures.
  • Created a Job Execution Sheet instructing technicians on how to complete the rework process.

Team Leadership

Led a group of engineers in designing an aircraft engine maintenance platform for HAECO, acting as team project manager and spokeperson to suppliers and stakeholders.

  • Planned weekly meetings to assign tasks and organized workshop hours to complete parts of the project.
  • Designated various research, report, and system roles to different team members based on skills and work load.
  • Managed hard deadlines using a Gannt chart for research, design, report, and presentation phases of project.

Product Design

Trailblazed an optimal product design through advanced discussion with team members and realized the full assembly in CAD using both custom and supplier parts.

  • Collected and discussed design ideas using combination charts and chose design features with help from weighted evaluation tables.
  • Determined cost effective yet high quality suppliers to provide parts for each subsystem.
  • Drafted the full assembly, each subassembly, and individual part drawings for manufacturer machining and integrator assembly.

Design, Time, and Cost Calculations

Ran hand calculations and FEA simulations to ensure design meets OSHA safety standards and calculated manufacturing time as well as budget constraints.

  • Hand-calculated platform extension bending stress and deflection, fastener hole bearing stress, fastener shear loads and stresses, maximum load capacity and weld stress of base members, and tipping moments for edge cases.
  • Estimated manufacturing time for each subsystem based on design specifications and available resources.
  • Analyzed costs for each subsystem based on combined material and part prices and integrator labor hours.

Front Wing Design

Led the design, simulation, and improvement of the front wing for the F24 (2023-2024 season).

  • Led a team of engineers in the design and implementation of new front wing elements and features.
  • Tested a variety of airfoils to determine which features optimized front wing performance needs for each element.
  • Designed and ran CFD simulations on various configurations to evaluate different airfoil sizes, positions, and attack angles to assess their impact on drag and downforce production.

Manufacturing and Design Process Improvement

Organized manufacturing operations and design progress to improve labor efficiency and design comparison.

  • Implemented a scheduling system for aerodynamics team members to improve personnel allocation and space utilization.
  • Fostered strong communication between leadership and aerodynamics team members through displaying updated progress in scheduling sheet.
  • Created spreadsheets organizing specific data points for each aerodynamic subsystem and tracked improvements over iterations.

Composite Materials Manufacturing

Manufactured 3 aerodynamic packages using composite materials such as carbon fiber and kevlar.

  • Conducted wet layup and curing processes for each part using vacuum bagging to shape elements and endplates.
  • Post-processed parts to remove excess material and achieve desired surface finish to reduce weight and drag.
  • Hotwired and CNC machined foam stock material into 2D and 3D molds.

Connect With Me!

561-419-5754 Copied!
linkedin.com/in/alex-e-vazquez