Matt Lambert

Seismic Analysis and Testing (Megapack 1, 2, 2XL) - Finite element modeling of battery enclosures, battery modules, and other subsystems - Testing enclosures and modules on seismic shake tables to IEEE 693 High PL - Coupon testing of back-to-back coupler assembly to 100's of kN - Test fixture design to match enclosure stiffness and validate battery modules - Working with third-party engineers to validate models and write reports Thermal Event Testing - Design of fixtures to test large format cylindrical cells with high vent pressure - Analysis of prototype designs for large format cylindrical cells with high vent pressure - Design and analysis of battery enclosure doors to withstand deflagration pressure - Design and analysis of retrofit parts to improve safety of installed products with thermal event deflagration risk - Design and analysis of deflagration vents and door capture mechanisms Charging Product Drop Analysis - Created explicit dynamic models of multiple charge handles (NACS, GB) and adapters (CCS) - Proposed and analyzed design improvements to exceed industry standard of 100 drops on concrete from 1 meter Design for Manufacturing - Brought enclosure manufacturing in-house in a new manufacturing facility - Worked to improve design of enclosure and battery module for automation - Solved manufacturing problems using first principles, detailed analysis, factory feedback, and manufacturing trials - Worked with manufacturing team to eliminate parts and joining processes to ramp Megapack 2XL to 200 per week (400GWh/year)

Product Development of Industrial Energy Storage Systems (Megapack 1, 2, 2XL) - Computer aided design of parts and assemblies Thermal Systems Mechanical Design - Collaboration with thermal engineers to optimize air flow and heat transfer - Mitigation of issues like thermal expansion of input louvers - Tolerance analysis of parts connected to large welded structures Computer-Aided Engineering - Finite element models of full Megapack as well as individual systems - Static analysis for lift, transportation, field installation, wind, and snow loading - Dynamic analysis of seismic, shipping vibration, deflagration, and drop Design for Manufacturing - Welding, stamped, bent, cast, and injection molded metal and plastic parts

Design, Analysis, and Testing of Energy Products, including Powerwall and Powerpack - Mechanical design of Powerwall 2 enclosure and mounting bracket - Developed and tested packaging for Powerwall - Design of Energy Gateway, to enable smart home connectivity of Powerwall 2 - Improved Powerwall yield through introduction of improved sealant material and process - Static and Dynamic Finite Element Analysis of Powerwall and Powerpack - Development of improved thermal system for Powerpack

Single axis solar tracker design, engineering, and testing for SunPower Oasis 2.x. Design, analysis, and testing of the C-Pile Drive Unit Foundation, which eliminated drilling, concrete, and field welding from Oasis trackers. Oasis 2.0 was rolled out at Solar Star in Rosamond, California, which is now completed and the largest solar power plant in the world at 579 MWac. Mechanical design, analysis, and testing of Helix Roof, a new commercial roof product for SunPower. An integrated, rail-less, tool-free design in which modules can be quickly installed with integrate spring clips. Both single-tilt (south facing) and dual-tilt (east-west facing) versions are available, and it is initially being offer for use with SunPower 96-cell modules. Dynamic modeling of wind load excitation of single axis solar tracker using MATLAB, Excel, and RISA 3D. Modeling of solar tracker equation of motion with various dampers, solving for system response with tested damper curves of various dampers to numerically determine the response to various test cases.

-Design of high accuracy solar tracker for Concentrator Photovoltaic System. -Experimentation using load cells, gravity-referenced inclinometers, and accelerometers to better understand the dynamic response, loading, and tracking accuracy of the tracker. -Analysis and design to increase the performance and manufacturability, and decrease the cost of the system for reduction of levelized cost of energy (LCOE).

· Dynamic, finite element, and fatigue analysis of tubular steel weldments, sheet metal parts, machined steel and aluminum parts with Solidworks Simulation, APA, and AISC. · Electromechanical systems engineering of 3-axis electric actuator motion system. · Integration of industrial AVG systems and powered casters in amusement park ride vehicle.

-Designed new 2-axis tracker system including castings, weldments, sheet metal parts, controller, hardware, and sensors using Solidworks 3D modeling, engineering drawings, ISO 9001 documentation, and FEA simulation.

-Designed, machined, and assembled (titanium) roll cage, suspension, carbon fiber chassis and steering. I participated in the full design and build cycle of two complete solar cars, Apogee and Xenith. Apogee finished 10th in the World Solar Challenge and 4th in the American Solar Challenge. Xenith finished 11th in the World Solar Challenge.

218, Stanford Frameworks, Stanford Solar Car Project.

Software development for a German solar inverter manufacturer. Developed modules to monitor key variables over TCP/IP and RS-485 using modbus. Also participated in marketing activities such as Inter Solar trade show, speaking with potential customers about the advantages of transformerless inverter design (efficiency!).

Contributed to development and cost reduction of high accuracy two-axis tracker for production concentrator photovoltaic systems. Carried out design, comparison, and testing of optical and magnetic angular encoder solutions for future versions of solar tracker.