Tesla: Model X B-Pillar

Complex Electro-Mechanical Design, Assembly, and Testing

  • Strengths demonstrated: Electro-Mechanical Design, Design for Assembly, Design for Manufacturing, Tolerance Analysis, Design of Experiments, Project Requirements Definition
  • Tools used: CATIA, 3D Printer, Thermal Chambers
  • Company Team: Tesla Autopilot and Electronics Product Design Team
  • Project date: 2020

What?
As the Mechanical Design Engineer for the sensors of the B-Pillar, I was tasked with upgrading the sensor suite for the Model X Plaid, which consisted of including space for a new bluetooth, NFC, UWB terminal & camera and determining the cause and most effective solution for fog the develops on the lens.

How?
Using CATIA V5, I studied the area around the B-Pillar including the body-in-white and collaborated with various teams to determine the space requirements for the new sensors. For fog testing I created an enclosure that let me replicate the fog and test various solutions such as heaters and hydrophobic coatings.

Results
The addition of the bluetooth, UWB and NFC sensors allowed for additional security and user experience feature for customers. The hydrophobic coating reduced the failure rate of the camera by over 30%, aiding autopilot consistency.