Mechanical & Simulation Engineer | CFD | FEA | CAD | R&D

Applied Eulerian Eulerian multiphase flow models with Rayleigh Plesset cavitation/phase change kinetics in ANSYS and STARCCM+ to resolve transient 130 PSIG steam condensation.

Utilized SST k-omega turbulence closures with prism layer mesh refinement (y+~1) near the injector nozzles to capture high velocity kinetic dissipation under a 4ft hydrostatic head.

Executed transient Conjugate Heat Transfer (CHT) to demonstrate a successful bulk fluid temperature ramp from 80 F to 170 F within the strict operational timeframe.

Validated buoyancy driven macro mixing velocity vectors, proving complete elimination of localized hot spots

and ensuring a uniform 48-hour adiabatic thermal hold across all 26,000 gallons.

Commissioned within a government backed energy program, this project delivered a centrifugal pump impeller for large scale pumping operations. The mandate was to increase efficiency and reliability while ensuring the design remained practical for industrial manufacturing and long term operation.

The impeller was developed in SolidWorks with multiple design iterations refining blade geometry and hub configuration. Performance was validated through CFD simulations in Ansys Fluent and StarCCM+, with a focus on reducing hydraulic losses, improving velocity balance, and extending cavitation resistance under demanding duty cycles.

The optimized design achieved a 14% efficiency improvement, a 20% reduction in hydraulic losses, and a 30% improvement in flow uniformity, while extending cavitation margin by 12% compared to baseline. These results directly supported project targets for lower energy consumption and stable long term operation.

Deliverables included a complete CAD package, a CFD validation dossier with flow visualizations, and prototype ready documentation for fabrication.

Media evidence is available in the project portfolio.

This project addressed uneven flow distribution in a dual inlet intake manifold intended for high-performance automotive applications.

The goal: deliver consistent air fuel balance across all cylinders while minimizing pressure losses.

A baseline model was developed in SolidWorks and iteratively refined. CFD simulations in StarCCM+ evaluated velocity distribution, pressure drop, and turbulence intensity across design variants. Runner geometry and inlet angles were systematically optimized to achieve uniform flow delivery.

The optimized design achieved a 4× reduction in velocity scatter, reduced pressure drop to 236 Pa, and secured <0.1% mass flow imbalance ensuring stable and efficient combustion conditions.

Deliverables included a complete CAD package, CFD reports with contour and streamline visualizations, and a validation dossier suitable for integration into performance engine programs.

Within a government backed energy program, a 14 inch Michigan Wheel DJ 355 propeller was redesigned to transform industrial scale mixing operations. The challenge was clear: eliminate stagnant zones that undermined process reliability and reduce escalating energy costs in continuous use tanks.

Using SolidWorks for CAD and StarCCM+ with MRF for simulation, the propeller underwent multiple design refinements. The final configuration achieved a 100% elimination of dead zones, a 12–15% reduction in energy input per cycle, and a 312 Pa lower pressure drop versus baseline.

This result established a new benchmark for energy efficient industrial mixing demonstrating how precision design and CFD driven optimization can directly deliver cost savings and operational resilience. The engagement concluded with deployment ready CAD assemblies, CFD validation reports, and a full optimization dossier for scale up.

Media Available in Portfolio and Pictures.

A motorsport client commissioned the complete design and validation of an off road ATV chassis and suspension system.

The mandate: engineer a suspension capable of withstanding 2g braking, 2.5g cornering, and 3g bump impacts, while balancing stiffness with a competitive strength to weight ratio.

The system was designed in SolidWorks, including chassis frame, suspension geometry, and mounting hardpoints. Structural validation was carried out in Ansys Workbench, where finite element analysis assessed stress distribution, deflection, and fatigue life under racing loads. Iterative refinements strengthened high stress regions without unnecessary weight penalties.

The final configuration achieved a Factor of Safety above 2.3 across all critical load cases, eliminating structural weak points and ensuring reliability for competitive racing. Deliverables included detailed CAD assemblies, validated FEA reports, and material recommendations, giving the client a ready to prototype suspension system engineered for endurance and performance.

This independent motorsport R&D initiative set out to create a Formula 1 front wing aligned with 2022 FIA regulations, with a mandate to raise aerodynamic efficiency while ensuring flow stability across multiple racing conditions.

The baseline geometry was established in SolidWorks and subjected to a structured CFD program in Siemens StarCCM+. Multiple design iterations explored flap profiles, chord ratios, and endplate refinements, with each cycle benchmarked against aerodynamic performance metrics.

The optimized configuration achieved an 8% increase in downforce and a 312 Pa reduction in pressure loss versus baseline, while significantly improving flow attachment at high angles of attack. Deliverables included validated CAD models, CFD reports, and aerodynamic visualization data, presented in a format directly transferable to prototype development.

The project was subsequently reviewed and commended by motorsport engineers, including professionals active in Formula 1 and Formula E Racing, reinforcing its technical quality and industry relevance.

As part of a competitive SAE racing team, I led the design and development of the braking system for a SAE class off road vehicle.

The mandate: deliver a system capable of reliable stopping power and endurance performance while introducing innovation to strengthen competitive advantage.

CAD models of calipers, rotors, pedal assemblies and master cylinders were created in SolidWorks, with FEA validation in Ansys for structural and thermal durability. The final design sustained braking loads equivalent to >2g deceleration, operated reliably under rotor temperatures exceeding 300 °C, and maintained performance over 4 hour endurance racing conditions.

For the first time in the team’s history, cutting brakes were introduced, reducing turning radius by 20% and significantly improving manoeuvrability in tight off-road conditions.

Deliverables included CAD assemblies, validated FEA reports, fully tested prototypes and lastly fabrication by hand on the actual race car. The final system combined robust endurance reliability with an innovative control feature that provided the team a measurable tactical advantage in competition.