Jordan Aguana

Mechanical systems integration lead - Managed 20+ part and subassembly revisions across multiple prototype units by coordinating design updates, verifying component compatibility, and tracking critical flywheel operational metrics for seamless integration - Performed detailed tolerance stack-up analysis on parts and assemblies, identifying potential fit and function issues early in the design process and driving corrective actions to ensure assembly reliability and performance - Achieved a 100% increase in prototype unit production and testing by process and resource optimization Flywheel enclosure designs - Designed large complex cast metal components for flywheel containment and electromagnetic assemblies - Created SolidWorks models and detailed drawings for geometry and GD&T definition, working with parts with tight tolerances in the 25-50 micron range, critical for controlling key flywheel operational metrics - Performed stress and stiffness analysis using ANSYS FEA, validating an intentional 25% increase in axial system stiffness to mitigate targeted resonance modes, optimizing flywheel dynamics for extended life cycling - Optimized part designs for machining by collaborating directly with in-house machinists to incorporate machining recommendations, ensuring designs were manufacturable and optimized for time and cost efficiency Prototype units build lead - Coordinated the assembly of 8 prototype units across four engineering teams to meet critical project milestones - Organized and led installation and preparation of prototype units at 2 remote test sites for rigorous testing - Reduced prototype unit assembly time by 40% by spearheading comprehensive technician training on complex assembly tasks, previously limited to engineers, streamlining workflow and optimizing personnel utilization

- Designed and implemented laser displacement instrumentation to track flywheel movements with micron-level precision during operation, contributing to the successful first integration test of a new motor-generator system - Reduced assembly delays by 25% through the development of specialized fixtures and tooling using rapid prototyping and various manufacturing methods, including 3D printing, CNC machining, and hand fabrication - Conducted thermofluid analysis to characterize heat generation and dissipation across powertrain components

- Assembled and tested over 50 automotive components including control arms, motor mounts, and flywheels - Operated machine shop equipment, including a hydraulic press, band saw, and drill press, for part fabrication

- Maintained clear and positive communication with over 200 campers and parents per week, ensuring high satisfaction ratings in end-of-camp surveys - Assisted in coordinating and running interactive camp activities, fostering teamwork, creativity, and an exciting atmosphere - Supported the camp director with logistical tasks, including scheduling, inventory management, and coordinating supplies for daily operations