1. DESIGN PORTOLIO
JAMES LE
Included in this document is a summary of the projects worked on outside of the regular curriculum through employment, as a member of the Society of Automotive Engineers R&D Team (SAE R&D), and through personal interest. It seeks to highlight the projects’ goals and responsibilities.

2. UF SOCIETY OF AUTOMOTIVE ENGINEERS (SAE) – R&D TEAM
Project – Carbon Fiber Control Arms
ROLE
Member of the Finite Element Analysis (FEA) Team.
PROJECT GOALS
To reduce the weight of the control arms for the suspension system while maintaining strength. We achieve this by collaborating with the design team and UF SAE members and analyze newly designed control arms, knuckles, and bungs.
PROJECT HIGHLIGHTS
 ANSYS FEA Software
 Design Optimization
 Collaborated with Test team and SAE to define boundary and loading conditions
 Created presentations for senior SAE members to communicate results
FEA – Mesh and Stress Results
REFLECTIONS
Joining a newly created design team and working in cross-functional groups for a single project was very rewarding. Not only did I get to learn the process behind FEA, but I got to build my teamwork skills and communicating skills between R&D members and SAE members. I got to learn a skill not learn in the classroom with industry leading software. The carbon fiber control arms are currently installed on the SAE formula car.
Proposed Control Arm Model

3. UF SOCIETY OF AUTOMOTIVE ENGINEERS (SAE) – R&D TEAM
Project – Carbon Fiber Brake Ducts
ROLE
Team Leader – Manufacturing Team
PROJECT GOALS
To build the components for a brake duct designed by the R&D design team. Learn the process behind carbon fiber manufacturing and lathe and mill machining.
PROJECT HIGHLIGHTS
 Created schedules for machining and carbon fiber mold manufacturing training
 Collaborated with UF SAE Composites Team
 Reported to R&D Team Captain and SAE Team Captain to communicate project results
 Interfaced with Design Team to design for manufacturability
 3D printing exposure with UF faculty
REFLECTIONS
Ultimately, the brake ducts were deemed unnecessary after testing of new brake rotor design. However, the project was very beneficial in learning what it takes to lead a team. Planning meetings, training sessions, and learning about design for manufacturability of were the key skills learned by the manufacturing team.
Proposed Carbon Fiber Brake Duct
Mold Manufacturing
Machining Training

4. Innovation Marine
Innovation Marine Corp
High Performance Diesel Engine Intern
 Optimized, updated, and checked part and assembly drawings using SolidWorks 2014 of a modified Cummins marine diesel engine implemented with a sequential turbo system for the Navy Special Warfare Development Group. (NSWDG formerly DEVGRU)
 Conducted finite element analysis simulations to for critical engine parts to meet Navy specifications.
 Project assistant for sequential turbo system testing and installation.
 Assisted in quality control, quality inspection and quality assurance of production turbo-diesel engines.
 Designed various parts to proper and ergonomic function of the turbo-diesel engine.
LEIDOS Prototype Navy Boat Space Frame Project by Michael Peters Yacht Design – Project Manager
 Project Manager for manufacturing of prototype frame
 Learned CNC programming using FeatureCAM to build frame
 Coordinated with vendors to order tools, stock, and material
 Created project schedule and managed project tasks
 Transferred CNC skills to diesel engine parts manufacturing and builds of personal designs

5. Innovation Marine
Experience Designing and producing my own parts in the CNC helped me understand its capabilities. I was able to develop efficient CNC manufacturing practices to ensure an accurate produced part. Taking part in the proof of concept and initial prototype phases of the Michael Peters project assisted in learning what it takes to design and manufacture a novel concept. Learning the capabilities of the CNC machine and examining part drawings from other engineers also helped me understand design concepts that would create functional and manufacturable design.
Space Frame Slide Tracks
Space Frame Slides
First CNC Part

6. Innovation Marine
Innovation Designs
Heat Shield
Given the opportunity to design parts for the High Performance Diesel Engine, LEIDOS Frame, and various other projects. Shown above is a Heat Shield concept designed to prevent the operators of the engine from burning themselves on turbo components. The heat from the exhaust fumes heated the metal to just above 1100°F. After making some assumptions, I was able to choose my own material, Inconel alloy, and ran through some simple hand calculations of radiation heat transfer. In theory, the heat shield would exhibit a temperature of 158° F, much lower than what is currently measured.
Heat Shield
Heat Shield Drawing Specifications – Material Inconel

7. Innovation Marine
Diesel Engine Quality Control Process
TASKS
• Participated in conducting measurements of parts to meet tolerance specifications
• Non-Conformance Reports (NCR)
• Work Instructions
Reports, NCR’s, and work instructions were reviewed by company president, director of engineering, and machinist to verify accurate data collection and clear communication of assembly process.
Non-Conformance Report
Work Instruction – Turbo Nozzle

8. Innovation Marine
FEA – Naval Special Warfare Development Group
ROLE
Using my previous experience using ANSYS FEA software, I was tasked in running simulations in SolidWorks Simulation. The main part being analyzed was a saddle for a heat exchanger, exposed to certain G-forces specified by the Navy. Wrote simulation reports and submitted to engineering director and Navy personnel for review and approval to part change.
HIGHLIGHTS
 Exposure to G-Force simulation
 New FEA software
 Formal Report submitted to NSWDG
EXPERIENCE
Learning a new FEA package was difficult but the methodology was still the same. Expanded my knowledge about FEA and allowed me to learn another FEA simulation package. Was relied on to run simulations of other engine parts to verify proper operation in the field. Was able to collaborate with head engineer at United States Marine Inc. in New Orleans. Gained experience in report riding for the Navy personnel and officers.
Heat Exchanger Saddle Mesh
Heat Exchanger Stress Results

9. Innovation Marine
Design Proposal
Was encouraged by the director of engineer to come up with a solution to turbo-lag in the production Cummins turbo-diesel marine engines. The design had to fit within the engine space of the boat and be reliable enough to work in harsh environments. I was also tasked in researching a possible motor-generator unit for the engine. The result was a 30 page design proposal submitted to the director of engineering for review. Currently being considered with the addition of a two speed transmission as a means to reduce turbo lag.
3D Section View Render
Design Highlight Flier

10. Senior Design
Heat Exchanger Design Project
Based on given design specifications, were tasked to design a Shell-and-Tube heat exchanger for crude oil and city water. Design was based on a hybrid of the Kern Method and other methods researched.
Project Roles
 CAD Designer
 Material Selection
 Cost Analysis
Final Heat Exchanger Design
Heat Exchanger Exploded View

11. Senior Design
Senior Design Project
During senior design, our design team was tasked to reverse engineer a Razor E300 electric scooter and report how it was made and manufactured. Due to my experience in researching of electric motors, I was the electrical systems lead, FEA lead, and brake design lead.
Electrical System
 Characterized the electrical system
 Defined functional requirements
 Created part and assembly drawings
Finite Element Analysis
 Created an accurate simulation of dead weight load and impact force on steel frame
Brake Design
 Explained the physics behind the band brake system used to control scooter speed
Using what we learned by reverse engineering the Razor E300 electric scooter, we were tasked to design a unique electric scooter that could fit in a carry-on sized bag.
Razor E300 Electric Scooter – Reverse Engineered

12. Senior Design
Advanced Scooter Concepts – XRS-C
Given the opportunity to create a company name and design name for a light, compact electric scooter. Key design requirements were that the scooter must be able to fit in a carry-on sized volume, and be under 23 lbs. Final design featured:
 Carbon Fiber
 High Torque
 Cruise control
 Fold-ability
 Ergonomic Handle Bars and Deck
Folded Design Render
Key Responsibilities
 Carbon Fiber Rim Design
 Mechanical Analysis – SolidWorks Finite Element Analysis (FEA)
 Electrical System

13. Senior Design
Mechanical Analysis
 Ran FEA Simulations for various load bearing components
o Carbon Fiber Tubing
o Rear Bungs
o Handle Bar Tubes
o Carbon Fiber Rim
Electrical System
 Calculated Battery Life
 Specified electrical components
o Battery Configuration
o Motor Output
o Controller Settings
Carbon Fiber Rim Design
 Design Carbon Fiber Rim
 Designed for Focal Point of Design
 Designed for Manufacturability
Carbon Fiber Rim Simulation - Simplified
Wiring Summary – XRS- C