About

I help teams turn concepts into manufacturable, cost-effective products, with fewer parts, easier assembly, and a faster path to volume production. 20+ years of mechanical design across batteries, power electronics, and data center cooling, including senior roles at Tesla (battery cell manufacturing equipment for Tesla’s 4680 cells, and mechanical design for the Dojo AI supercomputer) and APC by Schneider Electric (the EcoFlair data center air economizer and the EcoBreeze modular cooling line).

Proof points

• ~80% smaller footprint for Tesla’s 4680 battery cell formation equipment

• $90M per phase 4680 battery formation lines supported, Texas & Berlin (Tesla)

• 35% cost reduction on plumbing, sheet metal & weldments on the EcoBreeze unit (APC by Schneider Electric)

• U.S. Patent 10228196B2: large-scale modular indirect evaporative heat exchanger for data center cooling (APC by Schneider Electric)

• Tesla Dojo — mechanical design of the super-dense power supply for Tesla’s Dojo AI supercomputer cabinet

Services

DFM/DFA & part-count reduction — Fresh-eyes review to cut parts, fasteners, and assembly steps before tooling.

Design-to-cost & cost-down — Target-cost design and redesign of sheet metal, weldments, plumbing, and housings.

Concept-to-production design — End-to-end SolidWorks design, drawings, BOMs, and ECOs built for real factories.

Fixtures, equipment & line scale-up — Test fixtures, production equipment, and support for line setup and ramp.

Rapid prototyping & 3D printing — Production-quality prototypes built and assembled quickly.

Who I work with

Batteries & energy storage • Power electronics • Data center hardware • Aerospace • Hardware startups