Nicholas Przybysz's engineering design portfolio includes projects involving composites, structural metals, and automotive design. Some of the highlighted projects are a carbon fiber composite door with ballistic armor for the Tacoma, composite parts for motorcycles and snowboards, and designs for helmets, armor, and aerospace equipment. The portfolio demonstrates experience with composite layups, 3D printing, prototyping, and rebuilding vehicles.

1. Nicholas Przybysz Engineering Design Portfolio
Nick.przybysz@gmail.com

2. Overview
• Composite/Ballistic Projects
• Structural Metal Projects
• Automotive Projects

3. Composite Tacoma Door
• Full carbon fiber composite door with Level III armor incorporated into the door.
• All OEM parts transferred from donor door.
• Even with armor, there was a 10% weight reductions to the OEM door.

4. Ronin Racing Motorcycle Parts
• Built front and rear fenders, license plate holder, and gas tank/air box cover for the
small scale production of Ronin racing motorbikes. Parts were wet layup so fiber
orientation became a big concern and only perfect parts were accepted.

5. Composite Ski boot
• Snowboard boot with carbon fiber
exo-skeleton.
• Carbon fiber layup designed and
manufactured at at EBS Carbon
• Each pair of boots had over 100
carbon pieces in the layup that
were cut on a cnc cutting table.
• Article Here

6. Carbon Fiber Snow Shoes
• All carbon fiber snowshoe frame utilizing new carbon nanotube technology
• Article here

7. Composite Helicopter Helmet Face
Shield
• Carbon and
Kevlar composite
layup to achieve
frag protection.

8. Dimond Carbon Fiber Bike
• Did prototyping and initial production runs at EBS Carbon
• Used 3d printed multi-piece molds for frame and beam
• Read articles here and here

9. Composite Sports Helmets
• Made Warwick
goalie masks
used in the 2010
Winter Olympics
by Ryan Miller
and Evgeni
Nabokov
• High speed test
footage here
• Carbon fiber and
Inegra football
helmet designed
to reduce
concussive
force.

10. Composite Wheel Chalk
• Foam and Balsa chalks to replace 70 lb chalks for
mining dump trucks
• Weight had to be cut in half
• Hard to do design iterations when you have to shut
down a mine to test

11. Gofast Jetpack and Slingshot
• Custom molded backing
plate for hydrogen peroxide
jetpack
• Built platform for the Gofast
Human Slingshot that
premiered in Dubi for the
World Skydiving Competition
• See video here and here

12. Angel Armor Truth Snap Plates
• Worked on complete project from R&D to develop ballistic package through molds
and processes for production
• Two different levels of protection come together to create a third level of protection
• See Snap Plates on company website

13. Formed Ballistic Armor
• Mold made off of original
Micheal Keaton batman suit
mold
• 3 different levels of formed
armor protection
• Created formed armor plate
for femoral artery protection in
TALOS Military project

14. Vacuum Table
• Designed and built vacuum bagging table equipped with all bagging materials,
fittings, and hoses. It is mobile and can be moved around the shop as needed for
production.

15. Press Platin and Material Racks
• Press platin for use in 88 ton press
• Material racks to support rolls of pre-preg materials in the freezers.

16. 83’ CJ7 Rebuild
• Rebuilt from the frame up
• Regeared axles, trussed rear axle, fabricated diff covers roll cage, rear storage box,
and rocker rails. Many other upgrades to engine and drivetrain.

17. 96’ XR400 Rebuild
• Rebuilt from the frame up, top end engine rebuilt, shock rebuild and customization

18. Interprofessional Projects
• Designing and Building Prototypes to Assist
Blind Athletes
– Final design presentation here
• Improving Manufacturing Process Controls
– Design poster here
• Developing Affordable Solutions for the Worlds
Rural Poor
– Final design presentation here
• Power Measurement for Road Bikes
– Final presentation here

19. Senior Design for ITW
• Servo controlled 2 axis linear slide built
from scratch to position spray gun
nozzle for laser testing.
• Worked with small team of engineering
students to desing, program, test and
built, for ITW

20. Floating Arm Trebuchet
• Designed and built a floating arm
trebuchet for a interdepartmental
challenge.
• Learned to weld to build the uni-strut
frame
• Learned composite repair to repair and
extend the 14 ft carbon fiber throwing
arm.
• Was fully self sufficient, I could raise the
weights and move the entire thing by
myself