Deepening Professional Expertise

Define physically defensible loads, constraints, contacts, idealizations, and material data for a linear-static component FEA.

Perform a mesh-sensitivity check, distinguish singular stress peaks from converged structural results, and evaluate displacement, yield margin, and a declared safety-factor target such as 2.0 where justified.

Interpret supplied or synthetic mold-flow outputs for fill pattern, pressure, weld lines, air traps, volumetric shrinkage, fiber orientation, and warpage.

Create a drawing-convention plan that distinguishes ISO GPS—including ISO 8015, ISO 5459, ISO 1101, ISO 14405, and ISO 2692—from ASME Y14.5 and prevents unintended mixing of datum, dimensioning, and material-condition rules.

Derive ECU-housing requirements from applicable portions of ISO 16750, ISO 20653 or IEC 60529, relevant high-voltage safety references such as ISO 6469-3 where applicable, the declared GD&T system, and documented customer assumptions.

Perform a requirements-based trade study for PA66-GF30 and alternative enclosure polymers, including thermal, moisture, chemical, impact, dielectric, flammability, molding, and cost considerations.

Allocate functions among the ECU base, cover, gasket, fasteners, inserts, connectors, vent, PCB supports, shielding or isolation features, and vehicle mounts.

Select a static sealing concept and determine target gasket compression from supplier design data, compression limits, joint stiffness, and environmental exposure.

Define ECU interfaces to the assumed EDV mounting structure, high- and low-voltage connectors, vent, PCB, fasteners, electrical-isolation boundaries, and service envelope.

Create an initial controlled ECU product structure and approved requirements baseline using Onshape and supporting templates, including part numbers, metadata, CAD links, ownership, a preliminary EBOM, a proposed manufacturing view, and CATIA/ENOVIA mappings.

Construct an ECU standards-compliance matrix linking every applicable requirement to its source, rationale, verification method, acceptance criterion, owner, maturity, and evidence record.

Define an installed ECU ingress-verification procedure that distinguishes IEC 60529 IP67 from selected ISO 20653 protection codes and specifies conditioning, mounting orientation, test sequence, post-test inspection, and functional or insulation checks.

Create an ECU-housing master layout from the assumed EDV electronics-bay package, mounting hardpoints, keep-out zones, and harness approach directions.

Model the base and cover envelopes in Onshape while documenting the corresponding CATIA GSD and Part Design features, references, and command sequence.

Create uniform shell walls and 3:1 thickness transitions without trapping non-manufacturable geometry.

Model DFM-compliant screw bosses, inserts, ribs, gussets, and PCB supports for the ECU enclosure.

Model a gasket groove, compression stops, corner radii, and sealing-land continuity.

Create connector and vent openings with suitable retention, local sealing, electrical-isolation clearance, assembly access, and molding features.

Define the parting line, main-pull and texture-dependent draft, shutoffs, and any slides or lifters, then document the result with draft-analysis evidence.

Verify ECU-housing clearance to the EDV body, harness bend radii, connector access, fastener tool paths, and assembly-removal envelope.

Calculate a worst-case tolerance stack for gasket compression and sealing-land alignment, then compare the result with supplier compression limits.

Evaluate an idealized 30g ECU shock load case using assumed EDV mounting axes, housing mass, hardpoints, and a yield safety-factor target of 2.0.

Assess differential thermal expansion across the housing, PCB, connectors, inserts, and gasket, including its effects on sealing, fastener preload, and electrical clearances.

Interpret mold-flow evidence to revise ECU gate locations, weld-line positions, packing, shrinkage, and warpage risk.

Create release-ready base-and-cover drawing sheets under one declared ISO GPS or ASME Y14.5 system, applying functional datums, surface profile, position, system-appropriate maximum-material rules, and ISO 20457 molded-part tolerances where applicable.

Produce an AIAG-VDA DFMEA excerpt and derive linked special characteristics, validation entries, and preliminary Control Plan or supplier-control entries suitable for IATF-aligned evidence.

Complete an initial PLM release and present an ECU design-review package containing requirements, material and joining rationale, CAD and draft-analysis evidence, drawings, reconciled EBOM/MBOM views, DFMEA, validation evidence, PPAP-readiness records, risks, and change history.

Execute a supplier-driven ECU ECO by linking the issue, containment and 8D or 5-Why evidence, impact analysis, revised CAD, drawing and BOM changes, approvals, and released revision in the simulated PLM record.

Derive driver-door trim requirements for a declared target market by determining the applicability of FMVSS 302, ISO 3795, the selected GD&T system, customer appearance criteria, and documented fleet-duty assumptions.

Perform a material trade study for PP-TD20 and alternative interior-trim polymers.

Create an initial controlled door-trim product structure and approved requirements baseline using Onshape and supporting templates, including part numbers, metadata, CAD links, ownership, preliminary EBOM and manufacturing views, and CATIA/ENOVIA mappings.

Create an attachment and interface map covering clips, doghouses, screws, locators, pull and grab handles, switches, energy absorbers, mating trim, seals, and service points.

Define a datum and locating strategy on the assumed inner-door structure that stabilizes the carrier while accommodating build variation, thermal growth, and repeated door-slam loading.

Allocate B-side feature zones while protecting visible Class-A surfaces from sink, witness marks, read-through, and stiffness discontinuities.

Calculate initial EDV driver-door gap-and-flush budgets from styling targets, inner-panel variation, seal interfaces, attachment behavior, and adjacent trim.

Construct a door-trim standards-compliance and verification matrix linking flammability, dimensional, appearance, durability, and customer requirements to evidence records.

Import, inspect, heal, and organize assumed EDV driver-door Class-A geometry using CATIA GSD commands and equivalent available tools.

Develop a manufacturable B-side surface from Class-A geometry using offsets, extrapolations, blends, and controlled transitions.

Create the carrier boundary, return flanges, shutoff surfaces, and mating edges while preserving styling and gap-and-flush intent.

Model doghouses, clip towers, locators, screw attachments, and local load-introduction features with DFM-compliant proportions.

Design ribs and local reinforcements that minimize Class-A sink, read-through, and stiffness discontinuities.

Apply texture-dependent draft and verify the carrier against the tooling axis with draft analysis.

Create openings for the assumed EDV speaker, window switch, interior release, pull and grab handles, map pocket, and service points without compromising load paths.

Verify the EDV door-trim assembly sequence, clip access, nominal gaps, body-side clearance, serviceability, and mold side-action requirements.

Interpret door-carrier mold-flow results to assess gate strategy, weld lines, filling balance, shrinkage, fiber effects where applicable, and global warpage.

Evaluate local sink and rib read-through against a measurable zero-visible-defect acceptance method using declared lighting, viewing distance, surface master, and dimensional criteria.

Evaluate EDV door-trim clip retention, pull-handle loading, localized abuse, and repeated fleet-use loads with hand calculations or simplified FEA.

Calculate a worst-case tolerance stack for gap-and-flush alignment and clip engagement at a critical door interface.

Create a release-ready door-carrier drawing under one declared ISO GPS or ASME Y14.5 system, applying functional datums or datum targets, surface profile, position, inspection notes, and ISO 20457 tolerances where applicable.

Produce an AIAG-VDA DFMEA excerpt and derive linked special characteristics, validation entries, and preliminary Control Plan or supplier-control entries.

Complete an initial PLM release and present a door-trim design-review package containing requirements, appearance and material rationale, CAD and draft-analysis evidence, drawings, reconciled EBOM/MBOM views, DFMEA, validation and PPAP-readiness evidence, risks, and change history.

Execute a sink or warpage ECO by linking trial-build evidence, containment, 8D or 5-Why root cause, revised CAD and drawings, BOM impact, tooling action, approvals, and released revision.

Derive HVAC-outlet requirements for a declared target market by determining the applicability of FMVSS 302, ISO 3795, the selected GD&T system, customer airflow criteria, and documented fleet-use assumptions.

Perform a requirements-based material trade study for the outlet housing, vanes, linkages, bearings, and user-contact controls.

Create an initial controlled HVAC-outlet product structure and approved requirements baseline using Onshape and supporting templates, including part numbers, metadata, CAD links, ownership, preliminary EBOM and manufacturing views, and CATIA/ENOVIA mappings.

Define outlet rotation limits, pivot axes, clearances, operating efforts, and mechanism relationships within the assumed instrument-panel styling and package.

Translate an assigned EDV driver-zone comfort and defog airflow allocation into an effective-area requirement for the outlet flow path.

Define HVAC-outlet attachment, assembly, anti-rattle, and service strategies at the assumed instrument-panel and duct interfaces.

Create an interface-control model reconciling assumed styling, duct position, mechanism sweep, driver reach, displays, surrounding package, and owned versus supplied interfaces.

Construct an HVAC-outlet standards-compliance and verification matrix linking material, dimensional, airflow, effort, durability, NVH, and customer requirements to evidence records.

Construct the assumed driver-zone duct and bezel reference surfaces using CATIA GSD wireframe, sweep, fill, trim, join, and blend logic with executable equivalent tools.

Convert the outlet surface definition into manufacturable solids with controlled walls, flanges, and transitions.

Model repeatable vane geometry with aerodynamic leading and trailing edges and controlled spacing.

Create pivots, bearings, stops, and clearances that permit vane motion while controlling looseness, squeak, and rattle risk.

Model the vane-linkage and shutoff-control geometry from the kinematic layout.

Design snap fits, bosses, ribs, and duct-retention features for assembly and service requirements.

Define parting lines, draft, shutoffs, and undercut solutions for each molded HVAC-outlet component.

Verify HVAC mechanism travel, collision clearance, assembly sequence, service access, and interface fit within the assumed EDV instrument-panel package.

Calculate representative worst-case tolerance stacks for internal vane-and-pivot clearance and external bezel-to-panel fit.

Estimate outlet pressure loss and airflow distribution from effective area, velocity, and loss coefficients, then define a bench-test method for verifying the assigned airflow requirement.

Calculate stresses and safety margins for gloved actuation, mechanism stops, snap-fit retention, and representative abuse loads.

Interpret mold-flow results to improve HVAC gate position, weld lines, shrinkage, warpage, and dimensional stability.

Create release-ready HVAC drawing sheets under one declared ISO GPS or ASME Y14.5 system, applying functional datums, surface profile, position, fit controls, system-appropriate maximum-material rules, and ISO 20457 tolerances where applicable.

Produce an AIAG-VDA DFMEA excerpt and derive linked special characteristics, validation entries, and preliminary Control Plan or supplier-control entries.

Execute an HVAC packaging or tooling ECO under an IATF-aligned simulated ENOVIA workflow by linking the issue, root cause, impact assessment, revised CAD, drawing and BOM changes, approvals, and released revision.

Compile and present a consolidated company-style portfolio containing all three projects' standards register and compliance matrices, requirements evidence, CAD assemblies, draft analyses, released drawings, reconciled EBOM/MBOM views, quality and validation records, PLM baselines and ECO histories, design decisions, and open risks.