Ali Macias

Mechanical Design Engineer

Toronto, CA.

About

Results-driven Mechanical Design Engineer specializing in CAD-driven product design, FEA simulation, and design validation for vehicles, robotics, and aerospace systems. Proven ability to save costs and enhance product reliability, demonstrated by a $2.1M saving through structural system redesign. Expert in transforming complex concepts into manufacturable components, optimizing for both performance and production efficiency.

Work

Stellantis

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Design & Release Engineer

Toronto, ON, Canada

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Summary

Led advanced mechanical design and validation initiatives for automotive structural systems, ensuring production readiness and cost efficiency.

Highlights

Saved $2.1M by redesigning and validating hard top structural systems for Jeep Wrangler & Gladiator, enhancing vehicle integrity and performance.

Delivered critical engineering changes, ensuring DVPR compliance and achieving production launch readiness for new vehicle platforms.

Created and optimized complex CATIA models for mass production across global teams, improving design accuracy and manufacturability.

Improved product reliability by conducting root cause analyses and implementing structural design modifications, reducing failure rates.

Adient

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Engineering Intern

Detroit, MI, US

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Summary

Contributed to the design and release of advanced seating systems for electric vehicle platforms, focusing on safety, comfort, and manufacturing efficiency.

Highlights

Designed and released innovative seat structures, foam molds, and assemblies for high-volume EV platforms (Tesla Model 3, Mustang Mach-E).

Supported critical crash testing and ergonomic validation processes, directly impacting passenger safety and comfort standards.

Applied Design for Manufacturing and Assembly (DFMA) principles and CATIA modeling to streamline assembly processes, reducing takt time.

John Deere

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Mechanical Design Intern

Moline, IL, US

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Summary

Executed mechanical design and FEA simulations for agricultural machinery components, enhancing performance and manufacturability.

Highlights

Designed and validated a sheet metal bracket, reducing turbocompressor vibration displacement by 30% during tractor engine operation.

Conducted advanced FEA simulations to optimize the strength-to-weight ratio of components, improving material utilization and performance.

Improved manufacturability and reduced production cost through DFA-driven design principles.

Education

University of Toronto

Toronto, ON, Canada
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Master's Aerospace Engineering

Courses

Emphasis in Innovation and advanced manufacturing

Tecnológico de Monterrey

Monterrey, Nuevo León, Mexico
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B.Eng. Mechanical Engineering Grade: Ceneval Award Top 1% national graduates

Courses

Exchange in Germany

Awards

SECIHTI Scholarship for Master's

University of Toronto

Received a scholarship for Master's studies at the University of Toronto, recognizing academic excellence and research potential.

Ceneval National Graduate Excellence Award

Ceneval

Recognized as a top 1% national graduate, demonstrating exceptional academic performance in Mechanical Engineering.

Engineering Team Leader

NASA University Rover Challenge

Recognized for leadership in the NASA University Rover Challenge, guiding the team to significant improvements in rover capabilities.

Faculty of Engineering Best Project Award

Tecnológico de Monterrey

Received this award twice for exceptional project work within the Faculty of Engineering, demonstrating consistent innovation and quality.

Freudenberg Group Sponsorship

Freudenberg Group

Received sponsorship from the Freudenberg Group, supporting academic and professional development.

Bäden Württemberg Stipendium Scholarship

Bäden Württemberg

Awarded a scholarship for an exchange program in Germany, recognizing academic merit and international engagement.

Academic Talent Scholarship

Tecnológico de Monterrey

Awarded for outstanding academic potential and achievement at Tecnológico de Monterrey.

National Engineering Excellence Award

FIRST Robotics Competition

Awarded for innovative robotic design as Chief Engineer for the FIRST Robotics Competition team.

Languages

English

Spanish

German

Skills

Design & Simulation

SolidWorks, Fusion 360, CATIA, NX, Ansys, LS-DYNA, GD&T, FEA, DVP&R.

Engineering Skills

Mechanical Systems Design, Product Development, Rapid Prototyping, Additive Manufacturing, Injection Molding, Composites.

Testing & Validation

Structural Analysis, Root Cause Investigations, Durability & Reliability Testing.

Interpersonal Skills

Leadership, Teamwork, Cross-functional Collaboration, Innovation, High-Performance Results.

Projects

NASA University Rover Challenge

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Summary

Led a multidisciplinary team to design and develop a rover for the NASA University Rover Challenge, focusing on enhancing performance and efficiency.

Formula Student (Germany)

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Summary

Redesigned a carbon fiber rear wing for a Formula Student racing vehicle, prioritizing aerodynamic efficiency and stability.

FIRST Robotics Competition

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Summary

Served as Chief Engineer for a competitive robotics team, guiding the development of innovative robotic designs.