Sebastian Barquin Sanchez

Full-stack Engineer

Boston, MA, US

Matlab

SolidWorks

Autodesk Inventor

Rhino

Solidworks

Grasshopper

Microsoft Suite

CAD

Fusion 360

Python

MATLAB

Finite Element Analysis

ABAQUS

Microsoft Visio

Available for hire fromNegotiable

Mechanical Product Design Engineer & Thermal Simulation Engineer | AI-Accelerated Analysis | Sebar Design Engineering Team

Mechanical design engineer and thermal simulation engineer with experience in vibration/shock analysis, FEA/CFD simulations, and accelerating engineering workflows using AI coding tools and advanced simulation toolchains. Leading a small fractional engineering firm focused on consumer product design in the US. Previously led systems engineering for an FSAE team and completed R&D and manufacturing engineering co-ops at BorgWarner.

Projects

Copper 3D Printed Heat Exchanger for Cogeneration

Heat exchanger was designed after fin and cylinder tests showed 25 mm² solar panels illuminated by 1 m² mirrors reached 150°C under 600 W. To lower temperatures below 80°C, we created a compact 3D-printed copper exchanger with gyroidal supports, reducing simulation temperatures to 70°C. Final design was sent to Markforged for manufacturing and delivered to the client. Purpose. Research project design for sustainable energy lab to co-generate heat and hot waterSee More

Automotive Design & Aerodynamic CFD Analysis

A sleek, lightweight car body designed for a client pursuing a minimalist, performance-focused build. Careful attention was paid to packaging constraints, ensuring compatibility with existing mechanical layouts, while allowing for seamless assembly and maintenance. To optimize performance, we conducted aerodynamic CFD analysis to refine surface geometry and reduce drag, resulting in a visually striking, functional shell. The design was prototyped through 3D printing and refined iteratively to support low-volume fabrication for the client’s custom build.See More

Work History

Lead Designer

Sebar DesignFreelancerCollaborating with entrepreneurs on primarily sports consumer products. We see the ergonomic needs from feel to repeatability and haptics and apply durable mechanical engineering to the product. Our goal is to design products our clients are excited to use themselves. We also help clients in setting up their supply chain through methodical DFM with trusted manufacturers around the globe. We have worked with anything from precision gears to large rigid inflatables, ready to take on your product!

Mechanical and Thermal Simulation Engineer

Ford Motor Company● Simulated and analyzed vibration and shock use cases of high-performance hardware using Abaqus sequential programs, reducing total meshing time by 60% by introducing and teaching the new HyperWorks suite ● Improved FEA complete analysis speed by 2 weeks through AI coding tools to automate outdated processes ● Collaborated with vendors to produce 125 prototype models for PCB testing globally using Catia CAD ● Completed thermal steady state and transient CFD simulations for L3 computers with cold plates and forced convection modules which resulted in a 6-month schedule increase avoidance due to structural casting changes

Lead Systems Engineer

Cornell Racing (FSAE)May 2022 - Jun 2023 • 1 yr 2 mos● Developed a systems architecture model, optimizing competition points/action using existing and novel paths of macro-decisions which led to the team securing an increase from 8th to 5th place in the next year ● Implemented crucial changes to pedal system reducing issues by 50% using failure modes and effects analysis ● Streamlined manufacturing to reduce EV from-scratch fabrication time by 3 weeks, a team record for EVs to allow for one more month of testing, resulting in a gain of 20 places in the FSAE EV competition rankings

Research and Development Co-op

BorgWarner Turbo Systems Inc.Jul 2022 - Aug 2022 • 2 mos● Set the standard for tensile testing ANSYS simulations of carbon fiber rotor sleeves using anisotropic test data ● Reduced electric turbo test setup time by one month Visio diagrams and sourcing custom harnesses for testing

Manufacturing Engineering Co-op

BorgWarner Morse Systems Inc.Jul 2021 - Dec 2021 • 6 mos● CAD Designed and fabricated 20+ assembly robotic arms and fingers for picking up metal parts, saving $30k+ ● Parsed breakdown and operator downtime notifications, reducing analyzation time by 2 hours per machine, leading to a monthly decrease in downtime by 8 hours for each of the 4 machines, one day total savings

Education

Cornell University

Master of Engineering in Systems Engineering, Systems Engineering

Cornell University

Bachelor of Science in Mechanical Engineering, Mechanical Engineering

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