2025–2026 • Terps Racing Formula IC (Manufacturing Subteam Lead)
Chassis Jigging & Main Roll Hoop Bending
Assisted on 2026 chassis jigging before leading design and machining of the 2027 modular fixtures. Programmed an Okuma CNC mill to machine locating plates with 0.250″ dowel pin fits. Bent 1.000″ × 0.095″ chromoly roll hoops, compensating for springback, and used a mix of heat and sand to prevent wall thinning.
2025- 2026 • Power Electronics & PCB Design
Custom 6–28V to 5V Buck Converter & eFuse Protection
Designed a 6–28V to 5V (5A) buck converter in KiCad with integrated TI TPS26631 eFuse protection. Configured hardware UVLO, OVP, and 5.42A current limiting using resistor networks and soft-start timing. Resolved early gate-drive faults and optimized 2-layer PCB high-current loops and thermal routing.
2025-2026 • Data Logging & Telemetry System
ESP32-S3 GPS & IMU Kinematic Data Logger
Developed an ESP32-S3 vehicle dynamics logger to capture real-time chassis telemetry during track runs. Interfaced a u-blox MAX-M10S GNSS and 9-DOF IMU over UART and SPI. Eliminated buffer overruns under vibration to stream and log non-blocking CSV/GeoJSON kinematic data.
2026 • Terps Racing • Rapid Field Fabrication
Competition Emergency Shoulder Harness Bar Remake
Resolved a competition technical inspection failure by replacing a non-compliant shoulder harness bar under strict time limits. Interpreted FSAE structural rules to source and notch 1.000″ × 0.095″ chromoly tubing directly in the paddock. Fit and TIG welded the replacement assembly on-site, passing re-inspection to clear the vehicle for dynamic events.
2025 • Terps Racing • Shop Tooling
Custom Rotating Welding Table
Designed a motorized rotisserie welding table to eliminate out-of-position welds on circular exhaust assemblies. Turned center shafts and bearing journals on manual lathes to eliminate rotational backlash and runout. Integrated a foot switch for hands-free rotation, significantly cutting fabrication time and improving weld bead uniformity for the Terps Racing Powertrain subteam.
2024–2025 • Terps Racing Baja SAE
Baja SAE Front Nose & Toe Box Redesign
Led the front toe box redesign to optimize cockpit safety, reduce frame mass, and improve clearance against obstacles. Conducted FEA simulations to increase yield strength by 1.9% while cutting structural weight by 0.8%. Standardized AISI 4130 tube profiles to a 4.5-inch bend radius, eliminating costly tooling while streamlining fabrication.
2022–2026 • Karim Installation Workforce & Infrastructure
Structural Installations, Concrete Footers
Managed site preparation and full scale structural installation of heavy exterior architectural frameworks. Designed CAD models for load transfers through anchor bolts, hand excavated, and poured reinforced concrete pier footings capable of resisting overturning and frost heave moments.
2024–2025 • Terps Racing Baja SAE
Rapid Prototyping & Functional Additive Manufacturing
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2024 • Custom Mechanical Tooling
Custom Motorcycle Wheel & Tire Balancer
Designed and fabricated a wheel balancer capable of detecting sub-5-gram weight discrepancies on motorcycle wheel assemblies. Engineered 3D printed pedestal blocks housing de-greased, low-friction ball bearing pairs to minimize rotational stiction under heavy wheel loads. Modeled a custom stepped cone adapter to ensure concentric hub alignment along a rigid steel axle, successfully counterweighting the tire and eliminating high speed dynamic vibration during road testing.
Sept–Dec 2023 • ENES100 OTV Mechanics Lead & Embedded RF
Autonomous Water Mission OTV & ESP32 ELRS RC Conversion
Engineered a tool-less, modular clamping architecture for an autonomous Over Terrain Vehicle (OTV), allowing rapid motor subassembly swaps in seconds. Post mission, I refitted the vehicle with an ESP32 microcontroller and ExpressLRS receiver, writing custom C++ firmware to map incoming serial RF packets directly to the motor PWM drivers for manual RC control.
2023 • Automotive Powertrain & Hydraulics
2016 Chrysler Town & Country Transmission Overhaul
Diagnosed catastrophic internal slip in a Chrysler 62TE automatic transaxle by verifying line pressures and pulling trouble codes. Dropped the front subframe to perform a full teardown, successfully replacing the faulty transaxle, and reassembling to factory torque specs and recalibrating fluid levels.
2022–2023 • Avionics, Flight Controls & RF Hardware
5-Inch FPV Quadcopter & RadioMaster TX16S RF Hardware Mod
Integrated a high thrust 5 inch carbon fiber FPV quadcopter with 4-in-1 ESCs and filtered power distribution to prevent inductive voltage spikes. Modified a RadioMaster TX16S with a custom SMA coaxial connector and ExpressLRS module for low latency RF links, followed by dynamic Betaflight PID loop tuning to eliminate prop wash oscillations.
2020–2021 • Aerodynamics & Simulation
Aircraft Nose-Cone Sharpness CFD Study
Evaluated the aerodynamic tradeoffs between sharp, ogive, and blunt aircraft nose cones using CAD and computational fluid dynamics (CFD) on Autodesk CFD Ultimate. Validated mesh independence and plotted pressure distribution contours to analyze how nose radius alters drag coefficient.
2019 • PLTW School Project
Kinematic Projectile Launcher & Trajectory Modeling
Designed a multi piece parametric CAD mechanism and fabricated a physical projectile launcher featuring wooden dowel pin pivots, an elevation gauge, and tensioned elastic bands. Derived empirical muzzle velocity from baseline firing trials and benchmarked ideal theoretical kinematic models against real world aerodynamic drag and friction
2017 • Early Aerodynamics (8th Grade)
Scratch-Built RC Airplane — “The 7-Second Flight”
Constructed a budget constrained foamboard RC aircraft from scratch, utilizing repurposed skateboard wheels for the landing gear. To accurately shape the wing's airfoil, Imade a custom hot wire foam cutter by driving current from an ATX PC power supply through tensioned guitar strings. While an aft Center of Gravity caused a stall during its 7 second maiden flight, this early project served as my foundational catalyst for studying aerodynamic engineering