Minjae Kim

Context & Constraints

Vehicle durability testing exposed critical piezo sensors to harsh contaminants (mud, moisture) and vibration. Existing solutions failed to protect the $500+ sensors. The challenge was to design a cap that achieved IP67 waterproofing while remaining hand-installable for technicians across 20+ different bolt variants.

Engineering Logic

• Physics-Based Design: Derived a custom calculator using interference fit formulas to balance sealing pressure ($P$) vs. hand-insertion force ($F$). Defined optimal tolerance to ensure sealing without requiring tools.
• Material Selection: Prototyped and tested ASA, TPU, and Nylon against 3 criteria: Impact resistance, Water submersion, and Elasticity. Selected ASA as the only material to pass all validation stages.
• Automation (Powercopy): Developed a CATIA VBA script that instantly generates cap geometry based on bolt hex size. Turned a repetitive modeling task into a reusable parametric template.

Quantitative Impact

• 100% Data Integrity: Zero sensor failures due to moisture intrusion during endurance tests.
• 95% Time Reduction: Automated the design process, allowing engineers to generate new cap models in seconds rather than hours.
• Mass Production: Successfully deployed injection-molded ASA caps for the fleet.

Challenge

Manual processing of torque-to-failure data was time-consuming and prone to error.

Solution

Built a Python automation tool (Pandas, Numpy, Matplotlib) with a GUI for engineers to actively use during testing.

Impact

• Deployed to Gigafactories in Berlin, Shanghai, Reno, and Fremont.
• Saved 10+ hours of analysis time per joint.

Objective

Prevent connector joints on ReAX systems from damage during international shipping.

Engineering

Modeled 3 different connector types in PTC Creo. Applied GD&T to all parts and 3D printed for immediate usage.

Outcome

Final models were used for successful shipments to Germany and China facilities.

Design

Modeled front and rear wings using SolidWorks. Constructed airfoils using carbon fiber, aluminum end caps, and foam inserts.

Validation

Performed ANSYS CFD simulations and verified in the Purdue wind tunnel.

Results

• Optimized downforce and drag by 30%.
• Developed a standardized team-wide CFD process.

Designed and modeled a fully functional stirling engine assembled on a custom pirate ship model.

• Modeled 18 individually designed parts in Siemens NX.
• Applied GD&T for all assembly components.
• Utilized materials including brass, nylon, and polished metal.
• Total effort: 260 hours of modeling.

Reverse-engineered wheel spokes and exhaust manifold based on the Pagani Huayra Roadster.

• Modeled in Siemens NX with full GD&T application.
• Designed for manufacturing with Iron 40 and light weight alloys.

Identified safety risks at busy campus intersections. Designed an automatic roundabout system with ultrasonic pedestrian detection.

• Simulated traffic flow using MATLAB.
• Programmed signal display logic in C.
• Achieved 90% peer satisfactory rate.