Sean Phelan

Sr. Mechanical Engineer @ Cosmic Robotics

About

I am a Senior Mechanical Engineer with 3+ years of experience helping companies design, test, and optimize restraint systems for world-class electric vehicles. Some of my accomplishments include: Develop airbag performance to achieve top safety ratings and exceed regulatory requirements Worked with Design Studio and suppliers to deliver user-friendly, manufacturable steering wheels Managed development of an open wheel race car to winning first place at FSAE Michigan I’m excited about accelerating the world’s transition to sustainable energy. Green energy, satellite technology, and other projects that make life better for the future particularly interest me. I also enjoy rock climbing, snowboarding, surfing, and mountain biking. If you’re involved in any of these things, I’d love to hear about it.

Country

United States

City

San Francisco Bay Area

Industry

Automotive

Skill

Problem Solving, Root Cause Analysis, Product Development, Mechanical Product Design, Engineering, Siemens NX, Computer-Aided Design (CAD), Team Leadership, SOLIDWORKS, MATLAB

Experience

Sr. Mechanical Engineer

Cosmic Robotics

2026-4 - Present · 6 mos

Senior Mechanical Design Engineer

Tesla

2024-8 - 2026-3 · 1 yr 8 mos

- Implement feedback from testing and manufacturing engineering to improve performance and manufacturability - Led 3 suppliers to develop competing driver airbag systems during sourcing to reduce cost and optimize performance - Interface with CAE team to refine concepts to drive design changes and ensure new restraints meet 20% margin to regulatory limits

Safety & Restraints Mechanical Design Engineer

Tesla

2021-10 - 2024-8 · 2 yrs 11 mos

- Collaborate with Design Studio, Interiors Engineering, and suppliers to optimize steering wheels for manufacturability and user experience - Managed scheduling and sourcing for static, sled and crash tests, ensuring timely execution for homologation submissions - Delivered manufacturing improvements through innovative prototyping & rigorous deployment testing

Project Manager

Michigan Electric Racing

2020-3 - 2021-7 · 1 yr 5 mos

Ann Arbor, Michigan, United States

- Managed timelines to keep vehicle progress on schedule, winning first place at FSAE Michigan - Acquired new talent to create new Business Division to increase sponsor and community engagement - Facilitated merger between MER and MRacing to efficiently utilize resources available for student teams - Enact team policy to mitigate COVID-19 infection and keep 50 team members safe in workshop and testing environments