Simone Boninsegni

FribaRacingGroup is a mechanical engineering studio supporting companies facing complex or technically critical engineering challenges. Within FribaRacingGroup, I am typically engaged when projects are under pressure, requirements are incomplete, documentation is missing, or when standard engineering approaches are no longer sufficient. My role focuses on hands-on technical problem solving, mechanical design and system-level decision making, supporting companies during the most critical phases of development. I remain directly involved in engineering activities rather than operating solely in a managerial or supervisory capacity. I have worked across defense, automotive, motorcycle, industrial equipment and electric mobility projects, addressing high-risk technical issues related to performance, reliability, safety, manufacturability and cost. Activities include complex mechanical and electromechanical design, reverse engineering of legacy components and assemblies, redesign for manufacturing and additive processes, technical documentation, and definition of test and validation methodologies. Reverse engineering activities are supported by in-house 3D measurement capabilities (FARO CAM2 with 8th axis), enabling accurate reconstruction of parts and assemblies starting from incomplete or undocumented data. My involvement is typically structured as time-limited assignments, technical audits or focused support during the most critical phases of a project.

Served as Head of the Mechanical Engineering and Styling departments, with full responsibility for team selection, training and leadership, as well as technical direction across multiple motorcycle development programs. I led projects from initial concept through production, covering system architecture, detailed design, prototyping and validation through dedicated testing activities. A significant part of my role involved solving complex engineering and organizational problems, including unclear requirements, aggressive timelines and cross-department coordination challenges. I developed dedicated functional specifications—both internal and external—to streamline workflows and improve technical alignment across the organization. I worked closely with sales, purchasing, quality, production and aftersales, ensuring technical decisions were aligned with business constraints, supplier capabilities and cost targets, while maintaining delivery schedules and budget commitments. Throughout this role, I maintained a hands-on engineering approach, actively contributing to critical design decisions, troubleshooting and project execution. This eight-year experience involved highly demanding projects and challenging conditions; while not every challenge led to immediate success, my leadership, team cohesion and results-oriented mindset were consistently recognized and valued.

Served as Chief Engineer on the Support Equipment for the F-35 Lightning II program, leading the design and development of a military ground support crane intended for the maintenance of the engine and vertical lift system. Starting from supplier and program technical specifications, I conceived the vehicle architecture and operating logic, defining system requirements and leading all engineering activities from concept through detailed design. I coordinated and supervised structural design, calculations and analyses, manufacturing, assembly and final machine setup, ensuring full compliance with applicable MIL, ISO and SAE standards. A key part of my role involved solving complex engineering challenges related to safety, reliability, structural performance and operational constraints in a highly regulated defense environment. I led the project through final validation and acceptance testing, supporting test procedures and verification activities required by the program and ensuring readiness for operational use. This role required strong technical leadership, supplier coordination and rigorous engineering discipline, typical of high-criticality military applications.

Served as Technical Lead for the Ancillotti GA vehicle development program, with responsibility for the overall technical conception, mechanical design and styling integration of the vehicle. I led the mechanical engineering activities across the full development cycle, from initial concept through detailed design, working closely with suppliers to source both commercial and custom-engineered components. A key part of my role involved solving engineering challenges related to vehicle performance, reliability and manufacturability, balancing technical requirements with production constraints. I directly supported track testing and data collection, using test feedback to drive iterative design improvements and optimize vehicle behavior and robustness. In the final phase, I developed production launch schedules and cost plans, supporting the transition from prototype to series production.

Started as a Mechanical Designer, working on technical development and engineering solutions for high-performance motorcycle applications. Thanks to consistent results and increasing responsibilities, I progressed to become Head of the 125GP Research & Development Department, leading innovative projects from concept through prototyping and track testing. In this role, I managed the full development cycle of high-performance components and systems, applying advanced technologies such as reverse engineering, rapid prototyping, and iterative testing, to deliver cutting-edge technical solutions under strict performance and timeline constraints. I coordinated cross-functional activities and ensured technical alignment between design, manufacturing and testing teams, contributing to continuous performance improvement and product innovation.

Questa esperienza lavorativa rappresenta il proseguimento dell'attività di tesi di laurea e mi ha permesso di proseguire nel settore dei motocicli da competizione. Ho eseguito progettazione di ciclistiche 125 GP, dalla geometria ai calcoli agli elementi finiti affrontando infine le problematiche di realizzazione dei particolari. Ho eseguito analisi sperimentali con estensimetri a bordo del motociclo per la valutazione dei carichi reali sul telaio ho lavorato con i dati acquisiti dalla telemetria di bordo familiarizzando con le problematiche di setting ciclistico in pista. __________ This work experience was a continuation of my university thesis and allowed me to further pursue the competitive motorcycle sector. I worked on the design of 125 GP chassis, from geometry to calculations and finite element analysis, addressing the challenges of component manufacturing. I conducted experimental analysis using strain gauges mounted on the motorcycle to evaluate real loads on the frame, and worked with onboard telemetry data, becoming familiar with chassis setup issues on the track.