Mechanical Engineer CAD, FEA, Testing, Data Analysis

Alex Block

***********@*****.*** alexblock**.myportfolio.com US Citizen

Education

California State Polytechnic University, Pomona – BS in Mechanical Engineering Expected May 2026 Work Experience

Engineering Co-Op, Motion Conveyance Solutions – Riverside, CA June 2024 – September 2025

● Engineered conveyor capacity upgrades for 150+ projects by driving requirements capture, design reviews, and release of retrofit packages

● Prevented fit up rework on installs by modeling conveyor assemblies from BLK360 point cloud scans and clearing interferences before release

● Sized bearings and toleranced head and tail pulley shafts with overhung loads, validating stress and deflection against CEMA and internal criteria

● Verified drive frame and structural margins with hand calculations and Excel tools, implementing gusset and section upgrades to reduce peak stress

● Produced IFC and fabrication drawing packages including layouts, assembly drawings, and BOMs to support vendor quoting and field installation

Formula SAE Projects

Cooling Captain June 2025 - Present

● Sized radiator and coolant circuit for 8 kW heat rejection with 130% margin by building an NTU epsilon heat exchanger model using track-derived heat loads, CFD air mass flow, and venturi-based coolant flow data

● Reduced cooling loop pressure drop 13.8% by optimizing hose routing, minimizing bend count

● Achieved target radiator air mass flow by iterating sidepod, shroud, and radiator angle in CFD, driving updates to core volume and fan integration

● Derived endurance duty cycle and heat load inputs from MoTeC logs to set realistic coolant temperature rise and flow assumptions for sizing

Anti-Roll Bar Captain June 2024 - May 2025

● Designed adjustable U-style anti-roll bar system with rotational blade adjusters, 4130 torsion tubes, and Grade 5 titanium blades to expand tuning range

● Cut ARB stiffness adjustment time to 45–60 s from ~2 min per change by enabling rapid blade-angle tuning

● Correlated on-track potentiometer and IMU data to confirm roll gradient 0.378 deg per g front and 0.44 deg per g rear, meeting aero platform limit

● Verified endurance balance with MoTeC-derived mid-corner LLTD of 42.93%, inside the 0.39–0.47 target range Tires and Damper Tuning Captain June 2023 - May 2024

● Reduced IR tire temperature mount mass 0.64 lb to 0.28 lb by designing a carbon tube and machined-insert bracket that cleared full steering travel and maintained sensor alignment

● Rebuilt and recharged 4 Öhlins TTX25 dampers and validated force–velocity response on an Intercomp shock dyno to establish a repeatable tuning baseline

● Tuned low-speed damping using MoTeC potentiometer data, damper velocity histograms to identify ride-frequency issues and guide setup changes

● Coordinated with CNC sponsor to release and machine damper and drivetrain mounts Skills

● Design Tools: Autodesk Inventor, SolidWorks, AutoCAD, Autodesk ReCap, Leica BLK360, Leica Cyclone, Point Cloud Registration, Interference Checks, IFC Drawing Packages, BOMs

● Simulation and Analysis: MATLAB, Simulink, Mathcad, Microsoft Excel, VBA, SolidWorks Simulation, FEA, Bearing Selection, Shaft Tolerancing, CEMA Shaft and Pulley Stress, Pressure Drop Modeling, Pump Curves

● Testing and Fabrication: MoTeC i2, Arduino, FDM 3D Printing, Lathe, Mill, Drill Press

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