Custom Vehicle Platform
Partnered with a leading off-road vehicle company to design the next-generation platform. The team focused on its core competency: building advanced composite structures to the highest standard.
Features a fully redesigned vacuum-infused composite monocoque structure with aerospace-grade materials, an aerodynamic system, and a composite-reinforced torsion-free mounting system. Incredibly complex product — hundreds of individual component designs managed through master modeling technique with thousands of features and parent/child relationships.
Carbon Fiber Pass Through
Designed a pass through made from carbon fiber that perfectly complemented the Ram 3500 cab without sacrificing strength. Designed the mold which was built in-house.
Shell Segmentation Strategy
Devised a method to split a large composite shell into manufacturable sections with engineered joint geometry for structural bonding.
Foam Core Development
Countless hours developing the foam core geometry and layup approach. The shell itself is made of hundreds of individual foam parts, many requiring 2 or 3 machining operations and custom designed vacuum fixtures.
Integrated Subframe
Full torsion-free subframe design integrating the composite structure as a structural element. Instrumented testing procedure and data analysis.
Interior Systems
Designed composite interior systems end to end — mold design and fabrication, CNC-machined cores, assembly sequencing, fixture design, system integration, and fit & finish.
Swingout Tire Carrier
Designed a robust swingout tire-carrier that hauls a 40" spare with zero drama — no wobble, no resonance, just solid. Most carriers fight their own natural frequency. This one doesn't. Full ownership from design through fabrication fixtures, manufacturing drawings, and hands-on install across 5 customer vehicles.
Entry Stair System
Designed a fold-out entry stair system from concept through finished assembly. The customer touches this every single time they use the vehicle — so it had to be elegant, intuitive, and bulletproof. The perceived quality of a half-million-dollar build literally hinges on designs like this.
Configurable Platform
Designed components to support dozens of customer configuration options in a low-volume production environment.
Lead design engineer on the platform. Shell segmentation and joint geometry, composite mold design, foam core tooling, steel subframes and vehicle mounting systems, interior cabinetry, swing-out assemblies, stairs, exterior protection, manufacturing jigs and fixtures, CNC router programming, 3D printing and prototyping, work instructions, BOM development and ERP integration, supply chain management, and custom AI tool development.
A small, dedicated team producing an incredibly complex product — composites, structures, interiors, manufacturing, and systems integration. As lead design engineer, all core design work was my responsibility.
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