Improved inspection throughput 10% on a 2M+ parts/year production line 

GPA 97/110, ranked 1st on Italy's national engineering entrance exam 

Battery Lead behind 3 consecutive IHPVA World Records 

Set in Nevada on Sep 12, 2024, the fastest arm-powered vehicle record.

Set at Balocco on Oct 18, 2025, as part of Cerberus's arm-powered record run.

Set at Balocco on May 23, 2026, completing Cerberus's third consecutive world record.

• Designed a 12V LiFePO4 battery pack to power Pegasus's onboard electronics

• Powered gearbox controllers (Omero/Vertigo), position-feedback board (Refuso), telemetry, and vision system

• Benchmarked 26650 and 18650 LFP cell formats against capacity, discharge current, and cost

• Selected a 4S configuration to reach the required 12V nominal output (3.4 x 4)

• Split power into a 2S pack for Telemetry/Whereami and a 4S pack for Omero/Vertigo/Refuso to isolate sensitive signals from motor circuits

• Modeled the pack enclosure in Siemens NX

• Kept telemetry and GNSS signal cabling electrically isolated from high-current gearbox circuits

• Reduced electromagnetic interference risk across the CAN bus network

• Balanced capacity, discharge rate, and cost in the final cell choice

• Optimized the fork joint (steering-to-fork connector) for Pegasus, designed for SLM 3D printing

• Reduced part mass while maintaining structural safety under load

• Defined design space in SolidWorks and ran topology optimization in Altair Inspire

• Switched material from Al7075-T6 to AlSi10Mg (SLM-compatible)

• Validated with FEM under a 1000N load, simulating full rider + prototype weight

• Cut mass from 216.3g to 59.79g, a 72.36% reduction

• Maintained a safety factor above 1.5 with stresses well below yield strength

• 3D-printed a prototype for fit-checks prior to SLM production

• Purity control drove a 43.9% capacity gain at −20°C, confirmed in 18650 cells

• Optimal carbon coating gave a 58.2% capacity gain at −10°C and raised the TR trigger temperature by +43°C

• Combined strategy reached ~3x baseline capacity at −20°C

• Concluded LFP/carbon is the strongest near-term path; SSBs remain the long-term solution pending cold-conductivity breakthroughs

• Delivered a working OCV-R model validated across constant-current, pulse, and constant-power operating modes

• Discharge time scales inversely with C-rate, from roughly 9000s at 0.4C to roughly 1800s at 2C, with proportionally larger voltage sag at higher rates

• Cleanly separated the resistive voltage drop from the OCV baseline, both in steady discharge and under pulsed loading

• Derived and implemented I = [OCV(z) − √(OCV(z)² − 4RP)] / (2R) for constant-power discharge

• Higher power levels reach the voltage cutoff far sooner: roughly 2300s at 25W vs. roughly 12500s at 5W

• Ran FEM analysis on the Cerberus chassis as a sandwich carbon-PVC composite structure under pedaling loads

• Assessed composite ply failure risk across the frame's carbon fiber layup

• Applied pedaling load case to simulate real riding conditions in Hypermesh

• Evaluated results using the Tsai-Wu failure criterion for maximum ply failure across the composite layup

• Maximum composite failure index reached 2.126E-02, far below the 1.0 failure threshold, indicating a large safety margin

• Confirmed the chassis layup safely withstands combined bending-axial-torsion pedaling loads without static ply failure

• Validated structural integrity ahead of Cerberus's world-record attempts

• Laminated the wheel hubs in carbon fiber for Cerberus, following composite manufacturing standards

• Ensured consistent fiber orientation and resin distribution for structural strength

• Cut and laid up carbon fiber plies onto the hub mold according to the specified layup sequence

• Applied vacuum bagging over the laminate to compact plies and remove trapped air and excess resin

• Cured the part under vacuum, monitoring resin flow through the bagging film

• Wore respiratory protection (mask) to safely handle resin fumes during the process

• Produced lightweight, structurally sound wheel hubs used on Cerberus during its world-record attempts

• Ensured consistent lamination quality through controlled vacuum-assisted resin removal

• Designed the front fork assembly connecting to the driving wheel of Pegasus

• CAD-modeled and assembled the full fork sub-system in SolidWorks

• Produced the 2D drawing with GD&T for the fork-to-hub joint for production

• Modeled structural parts (clamps, brackets, steering knuckle, column) in Ergal (7075 Al-alloy) for strength, and the handlebar in carbon fiber for weight savings

• Assembled all parts, checking fit and interference between components

• Generated orthographic views, sections, and GD&T callouts (flatness, parallelism, profile tolerances) per ISO 2768-mK and ISO 8015

• Delivered an assembly-ready fork combining high-strength Ergal and lightweight carbon components

• Produced a fully toleranced, manufacturing-ready drawing ensuring proper fit with adjoining components

• Provided the mechanical basis for further structural validation (FEM/topology optimization)

• Quantified how four heat treatments (normalize, water quench, oil quench, quench + temper) shift the hardness–toughness–strength trade-off in AISI 1045 CD steel

• Verified the tensile fixture's bolts were safe at the machine's maximum load

• Prepared and stamped dog-bone and Charpy specimens, austenitized at 850 °C, then cooled by the assigned route

• Ran Rockwell C hardness (3 indentations per specimen), Charpy impact, and tensile-to-failure testing; pooled results across all lab groups to compare treatments

• Calculated bolt shear and bearing safety factors using Von Mises, with Tresca as a conservative check

• Mapped the trade-off: water quench 50 HRC / 2.2 ft·lbf / 0.8% elongation; normalizing 16 HRC / 35.6 ft·lbf / 7%

• Identified quench + temper as the best operating point, 37 HRC with 18.4 ft·lbf and 175 kpsi UTS

• Flagged an anomaly: oil-quenched UTS (180 kpsi) exceeded water-quenched (85 kpsi), likely quench-induced defects causing early brittle fracture

• Fixture bolts ran at a shear safety factor of 1.008, effectively at the material's shear limit

• Performed Brinell hardness testing on forged parts before machining, including a train piston head and a crank-shaft as part of post-forging property verification

• Confirmed the forging + controlled cooling cycle delivered the hardness specified for the grade, and that the part was within the machinable window

• Took multiple indentations across the cut face (crown toward hub) to check through-section uniformity rather than a single spot reading

• Measured indentation diameters and converted to HB, logging each location

• Compared readings against the grade's specified hardness band from the material data sheet

• Piston head measured 262–284 HB across five positions (mean ≈ 271 HB), well inside spec and tight enough to indicate uniform cooling with no soft or over-hardened zones

• Cleared the part for machining, avoiding downstream tool wear from an over-hard forging

• Linked hardness back to approximate tensile strength (~900–950 MPa) as a quick property check before destructive testing

• Ran FEM analysis on the Cerberus chassis as a sandwich carbon-PVC composite structure under pedaling loads

• Assessed composite ply failure risk across the frame's carbon fiber layup

• Applied pedaling load case to simulate real riding conditions in Hypermesh

• Evaluated results using the Tsai-Wu failure criterion for maximum ply failure across the composite layup

• Maximum composite failure index reached 2.126E-02, far below the 1.0 failure threshold, indicating a large safety margin

• Confirmed the chassis layup safely withstands combined bending-axial-torsion pedaling loads without static ply failure

• Validated structural integrity ahead of Cerberus's world-record attempts

• Delivered a fully assembled, functional cast aluminum hog trophy meeting all specified GD&T requirements

• Demonstrated integration of four distinct manufacturing processes (casting, CNC milling, CNC turning, laser cutting) into one cohesive assembly

• Validated that base thickness, hole location, and thread engagement provided secure mechanical assembly and consistent part-to-part fit

• Simulated open-die upsetting of a cylindrical billet using QForm forging simulation software

• Analyzed stress distribution and barreling behavior during compression

• Modeled the billet and die geometry in QForm and ran the compression simulation

• Tracked mean stress evolution and barreling as the billet deformed between the dies

• Captured the classic barreling pattern expected in frictional upsetting

• Validated peak stress concentration at the billet's equatorial bulge, consistent with forging theory

• Completed simulation with full solver convergence

• Modeled the finished part in SolidWorks, then applied machining allowances and thermal shrinkage to derive cavity dimensions

• Designed the full cavity cross-section (land, flash, gutter) with fillet/draft callouts, breaking it into discrete volumes (V1-V7) for load calculations

• Learned fluorescent magnetic particle inspection (MPI) to detect cracks on forged transmission components

• Performed dimensional inspection of finished shafts against engineering drawings

• Applied fluorescent magnetic solution and inspected parts under UV light, where crack indications glow due to magnetic flux leakage

• Flagged forged shafts showing crack indications before further processing

• Measured critical dimensions with a height gauge and cross-checked against GD&T callouts on the drawing

• Gained hands-on exposure to NDT crack-detection methods used in OEM quality control

• Helped prevent defective forged parts from advancing in production

• Practiced linking dimensional measurements to GD&T requirements on real production drawings