Multimatic, Design Engineering - Suspension

May - August 2024

I supported the suspension design engineering department in Multimatic's Technical Centre (MTC), for my final 4 months. Some of my core responsibilities were:

• Designing components in CATIA V5 and Siemens NX, editing/updating designs.

• Applying surfacing and solid body modelling techniques to design stamped sheet metal, forged, and plastic injection molded parts.

• Creating or updating technical drawings and GD&T; maintaining conformance with ASME Y14.5.

• Co-ordinating prototype fabrication, testing, and analysis.

• Conducting assembly tolerance stack-up analyses.

• Analyzing test data. Processing vehicle sensor data.

• Processing 3D scans in Geomagic Studio.

• Working on reports: Design Failure Mode and Effects Analysis (DFMEA), Customer Test Specifications (CTS), and Design Verification Plan and Reports (DVP&R).

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An accomplishment of mine, is contributing to the quotation/acquisition phase of a program, for a popular truck.

• I designed multiple components and created component/assembly drawings.

• There were multiple product options, I created packages for each option containing CAD, drawings, and a presentation.

• Additionally, I created a presentation comparing components and manufacturing processes between each option.​​

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Multimatic, Design Engineering - Mechanisms

September 2023 - April 2024

I supported the mechanisms design engineering department in Multimatic's Technical Centre (MTC), for 8 months. My core responsibilities were very similar to those shown above.

• I learned surfacing and solid body modelling techniques to design stamped, cast, and plastic injection molded parts.

• I created detailed 2D drawings for various fabrication and assembly techniques:

  • Welding, fasteners, snap-fits.

• I worked on a bill of materials (BOM), and completed mass/CoG breakdowns for an assembly with 100+ components.​

 

A responsibility I was given, was to manage all design tasks for one subsystem in a next-generation complex mechanism. This was directly before a manufacturing plant began production of the product. This involved:

• Updating designs and drawings based on prototype testing results.

• Performing structural analysis using CATIA to validate designs.

• Creating a calculator in Excel to estimate the subsystem's performance.​

• Performing a kinematic study regarding the motion of the part - creating kinematic simulations and swept volumes using CATIA.

• Conducting tolerance stack-up analyses, and coordinating 3DCS tolerance analysis.

• Collaborating with third-party suppliers to ensure design for manufacturability (DFM).

• Presenting these design changes, drawings, analysis, calculations, and kinematics to lead design engineers, process engineers, and a manufacturing plant's general manager.

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Honda of Canada Manufacturing, Product Engineering - Interior

May - August 2023

I supported the product engineering department at Honda of Canada Mfg.'s factory, for 4 months. The majority of my work was related to Buzz/Squeak/Rattle issues in the interior of Civics and CRVs. Some of my tasks were:

• ​Conducting root cause analysis, using dynamic multi-post stands, test tracks, collaborative robots and environmental chambers.

• Supporting prototype testing, I helped set up collaborative robots for long-term durability tests.

• Configuring sensors like impact hammers, accelerometers, microphones, and thermocouples; collecting and processing data.

• Presenting results to collogues and supervisors.

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Royal Military College of Canada, Junior Researcher

Part - Time: January - April 2023

I supported the turbomachinery research group at the Royal Military College of Canada, for four months on a part-time basis. I researched flow control techniques in aircraft engine S-ducts.

• RMC has spent years developing a rectangular to circular S-duct. 

• My task was to design a duct in Solidworks to improve flow characteristics by manipulating the cross sectional shape.

• I used "Gerlach" shaping where the duct is designed so that velocity is increased at the outer wall and decreased at the inner wall of the first bend. This solution mitigates the natural geometry of an S-duct. This is achieved by narrowing the duct at the outer wall and widening it at the inner wall, resulting in a trapezoidal inlet face, rather than rectangular. As a result, the pressure gradient between the walls is reduced, without changing the average flow velocity.

• I designed the duct and all required components for testing in a transonic wind tunnel. I prepared models which were 3D printed, and 2D drawings.

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Royal Military College of Canada, Research Assistant

May - August 2022

I worked in the turbomachinery research group at the Royal Military College of Canada, for four months. I independently operated a wind tunnel, this involved:

• Collecting data to validate airfoils designed by the United States Airforce Research Laboratory (ARFL), which represent a 2D simplification of compressor blades within a jet engine.

  • AFRL additionally provided airfoils with "tubercles" which are small, rounded bumps, protruding from the leading edge of the airfoil. ​These are found to improve flow characteristics of certain animal structures, like whale flippers.​

• Setting up the wind tunnel to test under different conditions, different angles of attack and speeds.

• Using pressure tap and velocity probe data to calculate performance metrics in MATLAB, and compare to CFD predictions from AFRL. Additionally, using these performance metrics to determine whether the tubercles are effective.

• Presenting results to supervising professors.