The EcoCAR EV Challenge is a four-year advanced vehicle technology competition sponsored by General Motors (GM) and the U.S. Department of Energy, aimed at developing autonomous and electric vehicle systems. As a Mechanical Engineer on the System Design and Integration Team, I worked on multiple projects to redesign and integrate new powertrain components into a modified 2023 Cadillac Lyriq.

My main projects included redesigning the subframe, motor mount, and half-shaft to accommodate a new motor. Due to the motor's incompatibility with the Lyriq’s original subframe, we extended and reinforced the subframe by cutting the back and adding supporting material, following GM’s specific load conditions and stress analysis requirements in Simens NX and Simcenter. For the motor mount, I assisted in visualizing a replacement to ensure it aligned with the new motor’s specifications.

My ownership project was designing the half-shaft to solve three critical issues: converting a male-to-female connection (from the motor to half-shaft), correcting driveline alignment, and addressing the new motor's asymmetrical geometry. I engineered a stub shaft to bridge the female motor output and female half-shaft, accounting for CV joint allowances to maintain drive quality. The final design included a male-to-male stub shaft and custom bearing blocks for stability. Before final manufacturing, I created a CNC and 3D-printed prototype to test dimensions, allowances, and spline fit.

In addition to design and analysis, I developed assembly drawings with GD&T tolerancing, coordinated with manufacturers and industry experts, and managed communication within our team and with external stakeholders. 

Date 

• January 2023 - Present

Relevant resources for more information

• EcoCAR EV Challenge Information 

• EcoCAR UCD Information 

• EcoCAR UCD Homepage

Key Skills

• Simens NX, Simens Simcenter 3D, Manufacturing

• Project Management: Confluence, Jira

• Collaboration, Communication, Problem-Solving, Documentation, Adaptability, Critical Thinking