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MECHANICAL ENGINEER
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PROJECTS

PROJECTS
VEHICLES

VEHICLES

SKETCHES

SKETCHES

EXPERIENCE

EXPERIENCE

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Product Engineer
TREMEC Electric GT
  • ​Designed, analyzed, and documented sheet metal, CNC-machined, and 3D-printed components for high-voltage battery systems
  • Coordinated with international teams to develop and manage complex CAD models and engineering drawings, ensuring design accuracy and manufacturability
  • Collaborated cross-functionally with purchasing and manufacturing teams to resolve sourcing challenges

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October 2023- Present

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Lead Designer
EVOD Industries
Custom one-off components for high-end cars
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  • ​Created highly accurate 3D models using 3D scanning with customization based on customer design sketches
  • Developed a novel design for 3-piece center lock wheels with hidden fasteners and integrated brake hat for award-winning Twelveair show car
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June 2023 - October 2023

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Mechanical Engineer
Leidos
Design of hydraulic actuators and workstation for X-ray scanner truck

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August 2021 - May 2023

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  • ​Designed and conducted FEA analysis on sheet metal and CNC machined components to withstand harsh operational environments while minimizing weight

  • Developed heavy duty hydraulically actuated suspension locks and X-ray source locks

  • Engineered a deployable operator workstation desk, maintaining OEM design aesthetics

  • Conducted failure analysis and implemented design improvements to enhance durability​

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Mechanical Engineer
Meritor 
Design of components for heavy duty electric drivetrains for large trucks

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Jan 2021 - July 2021 (Contract)

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  • Designed sheet metal and machined components to mount electronics in Power and Control units

  • Designed high voltage cable runs with bracketry and documented low voltage control harnesses

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Mechanical Engineer
Global Air Logistics and Training, Inc.
Aerospace Communications Prototyping

 

May 2018 - October 2020

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  • Developed experimental airborne communications nodes 

  • CAD modeling in SolidWorks

  • Designed communications networks (ethernet, serial, RF)

  • Designed mil-spec cables

  • Sourcing & vendor management

  • Prototyping and testing new designs

Mechanical Engineer
GoWesty Camper Products 
Automotive Aftermarket Part Supplier

 

August 2016 - May 2018

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  • Developed new products for Volkswagen Vanagons

  • Launched replacement electronic fuel injection system

  • CAD modeling in SolidWorks and OnShape

  • Design for low volume production and retrofit interfacing

  • Sourcing & vendor management

  • Product improvement and support

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Mechanical Engineering Intern
SAIC/Leidos

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June - September 2013

December 2013 - January 2014

June - August 2014

June - September 2015

 

  • Assembled X-ray scanner vehicle prototypes

  • Modeled systems in Solidworks

  • Reverse engineered betatron X-ray source unit

  • Lead hydraulic stabilizing system integration from concept to production

  • Designed X-ray detector alignment brackets

  • Interacted with vendors for part design and sourcing

SKILLS

SKILLS

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Twelveair

CAD Modeling

Documentation

Sheet Metal

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Flight Hardware Design

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3D Printing

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RF Systems Design

Hand Tools

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Cable Design

MIG Welding

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Fuel Injection Tuning

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Network Design

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Dyno Tuning

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Prototyping

Machining

Radiation Safety

EDUCATION

California Polytechnic State University, San Luis Obispo

BSc, Mechanical Engineering-June 2016

Dean's List- Winter 2012, Spring 2013

GPA 3.11

Tech Electives

Vehicle Dynamics

Mechanical Experiment Design

Industrial Automation

La Costa Canyon High School

President, Engineering Club

Graduated June 2011

GPA 4.32

EDUCATION

Let's talk

CONTACT

© 2023 Michael Saggese

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