Sebastian L. Valero

Cell: 713-***-****

Email: ad4rbg@r.postjobfree.com

EDUCATION:

Louisiana State University (LSU), Baton Rouge, LA May 2022 Bachelor of Science, Mechanical Engineering

EXPERIENCE:

VEC Technologies April 2023 – Present

• Design, model and build custom tooling and composite parts for automotive and marine applications

• All products are designed in SolidWorks and all final parts are made of either Infused Carbon Fiber or Fiberglass Flowserve Corporation – IGNITE Engineer Pump Division June 2022 – April 2023

• Responsible to analyze and reduce the PSR’s (Product Service Reports) by 50%

• Worked within the Quality Engineering department and reduced manufacturing errors throughout the Pump Division LSU Tiger Racing, Formula SAE – Team Captain / Chief Engineer August 2015- May 2022

• Collegiate team designs and builds a 2/3 scale Formula 1 car to compete in international competitions

• Captain / Chief Engineer of the 2020 and 2021 teams covering all subsystems of the car

• Used CFD software Star CCM, to aid in the aero package design and validated with wind tunnel results

• Lead Engineer for Aerodynamics, Intake, Chassis, Oil, Engine Internals, Suspension Components, Drivetrain o Used CAD, CFD and FEA software’s during the engineering process

• Managed, led, and supervised a team of 40+ engineering students

• Responsible for acquiring sponsorships and managing finances

• Top 10 in Michigan SAE Endurance Race in 2019, 2020 and 2022, with over 100 teams worldwide

• Top 7 overall at Michigan 2022 Formula SAE competition LSU Advanced Manufacturing and Machining Facility (AMMF) Summer 2018-2021

• Summer intern at LSU AMMF shop, also worked part time during the school year

• Fluent in CAD and CAM in order to manufacture with lathes, mills, waterjet, CNC, and 3D Printers

• Assisted in the design and manufacturing of prototypes for customers

• Qualified in Tig and Mig welding

Project MFG Regionals May 2019- Nov. 2020

• National Manufacturing Competition to test one’s skills in 5 Axis CNCing and Tig Welding

• Used Mastercam software to program 5 Axis G-Code

• A member of the 1st place team in May 2019

SKILLS

Technical: Solidworks (CAD), Star CCM+ (CFD), Altair (FEA), Mastercam (CAM), Wardjet (CAM), Microsoft Office. Manufacturing: Mill and Lathe (CNC and Manual), Waterjet, 3D Printers (All types), Welding (Tig&Mig), Carbon Fiber (All Fields), Fiberglass.

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LSU Tiger Racing Team

This CAD render above was made using SolidWorks and is the 2020/2021 LSU FSAE car that I was elected Captain for and over saw the entire team as the Chief Engineer, managing all of the engineering and administrative aspects of the team.

2020 LSU FSAE Car CAD Render

Chief Engineer / Captain

Portfolio:

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2nd Order Simulation Residuals Showing Time Step Convergence Shown are Streamlines of the Vortex Tube on the outside of the Undertray in Star CCM+

CFD / Aerodynamics

2020/2021 Aero Package Components

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I was the first member to use 3D CFD and Star CCM+ in the team’s history and have designed the last two Aerodynamic Packages, being the Aero Subsystem lead since 2018. Using the CFD software Star CCM+ made by Siemens, the complete car is simulated in an abundance of simulations to acquire data for the aerodynamics packages, its correlation with the car’s kinematics along with the cooling subsystem. All full car simulations are 2nd order unsteady simulations solved with an SST K - Omega solver with residuals results reaching a 3rd order of magnitude or greater for each time step. Simulations also take into account rotating tires, moving ground and radiators created using a porous media feature. All simulations are run using Nimbix cloud supercomputing. Each aerodynamic package is then wind tunnel tested at A2 in North Carolina to validate the CFD is below a 5% margin of error.

2020 Aero Package at A2 Wind Tunnel

CFD / Aerodynamics

2019 Aero Package Wind Tunnel Vs CFD Comparison

CFD Vector Scene on the Rear Wing Illustrating the Boundry Layer Thickness 5

Every part that was designed for the car was FEA’d and confirmed through me as the chief engineer before being sent to manufacturing. Each FEA was checked by re-working the hand calculations to re-running the simulation to ensure loads were applied properly and that it reached convergence. Above are just two of the many FEA’s I have simulated over the years.

Finite Element Analysis / FEA

Front Uprights Made of 7075 Aluminum

Front Wheel Hubs Made of 7075 Aluminum

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Drawings

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These are just a few drawings I have made over the years, first being a master of the car with some sub- assemblies that were required for the FSAE competition. The next two are the front upright and rear hub that consist of magnitude of critical dimensions. Lastly is a frame drawing that depicts each tube and their corresponding dimensions, which was sent out to VR3 to have the frame tubes cut and coped. Drawings

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Manufacturing

These are the 2020 cars hubs and uprights seen in the previous drawings above which were made on a HAAS CNC lathe and VF-2 Mill. All parts for the car are manufactured in house at LSU from manual mills and lathes to CNC machines in which I was fortunate enough to be able to operate over the years. I have a rich amount of experience from starting a design to the finished product in an engineered component, which is very helpful in every engineering phase.

Front Upright in HAAS VF-2

Front and Rear Hubs and Hub Nuts

Front and Rear Uprights

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FSAE Frame

2020 Frame CAD Model with Jig Plate

2020 Frame Fully Welded and Painted

2020 Frame Tack Welded in Jig

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A Couple of my Welds on Frame Tubes with a 0.028-inch Wall Thickness 4130 Chromoly Steel 3D Printed Bell Crank Jigs

FSAE Frame

The Frame is one of the largest tasks to tackle on a Formula SAE car and I have had the opportunity of working on three of the frames over the years. The two most recently built frames for the 2021 and 2022 car was designed and built entirely by myself since I was the only member on the team with previous frame experience as well as the only welder. The frame is easily one of the most daunting tasks I have ever faced, from CAD modeling, designing custom jigs, ensure suspension points and other critical dimensions are met, to Tig welding hundreds of nodes and tabs with most tubes being 0.028” thick 4130 chromoly steel. 11

Project MFG is a Manufacturing and Welding National Competition organized by the US Government D.O.D. and NIMS to challenge the skills of the Manufacturing Industry. I have competed in two Project MFG competitions one being in 2019 as seen in the picture above in which we won and second being in November 2020. The competition grading is complex and largely based off time efficiency and management while completing the tasks of using Mastercam to write the CNC code, Machining complex 5 Axis CNC parts, Tig Welding aluminum and accuracy. More can be found on their website here: https://www.projectmfg.com/. I was in charge of the Tig welding and programming the CNC code using Mastercam for each competition. Here is an article about us winning the 2019 competition: https://www.lsu.edu/eng/news/2019/07/dodibas.php Video of my team and I in 2020: https://www.youtube.com/watch?v=Zi-sp-9_7w0 2019 Competition Finished Billet Products

Group Photo with the other Teams from the 2019 Competition Project MFG Competition

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