Hey! I'm Jaffer.

I'm a mechanical engineering graduate looking for jobs in the Bay Area. I've worked on and done just about everything, like...
Brain Implants

Want to get in touch? Contact me on LinkedIn

I Have Experience in Design, Validation, and Manufacturing

neuralink logo

Neuralink - Mechanical Engineer

Jun 2024 - Aug 2024

Austin, Texas

apple logo

Apple - Manufacturing Design Engineer

May 2023 - Jan 2024

Cupertino, California

anduril logo

Anduril Industries - Manufacturing Design Engineer

May 2022 - Aug 2022

Marietta, GA

Design

Over the past four years, I've designed hundreds of parts including CNC-machined and snap-fit injection-molded components as well as simpler 3D printed and lasercut parts.

Simulation

From using topology optimization to lightweight parts to using structural simulations to narrow down snap fits, I simulate and validate all my components in FEA. I've also developed physical test fixtures and methodologies to validate these simulations in real life.

Manufacturing

I've written CAM in HSM and Mastercam for dozens of complex multi-fixture components in materials like titanium and stainless. I also have mass-production experience working with overseas suppliers at Apple.

structural simulation

CWRU Baja Design: Rear Upright

I completely redesigned our teams rear-upright for manufacturability using a first-principles approach. I effectively cut the part's size in half while maintaining all suspension-related requirements, reducing machining time, stock cost, and overall weight.

Axis and Vise fixture

This part was a 4th axis fixture along with a vise fixture. CAM was written in HSM and machine time was reduced from ~8 hrs to 4.

rear upright
nonlinear dynamic simulation

Nonlinear dynamic simulation of the entire assembly. In order to get more accurate results of various wheel impacts, and properly model the bearing stress on the upright, I ran FEA on the entire assembly instead of the individual part.

rear upright

The upright integrates with the rest of the rear suspension assembly, and is designed to have zero camber gain over travel.

CWRU Baja Design: Front Halfshafts

half shaft

I designed our front half-shaft assembly for the 2022 season as well. It’s validated to take up to 2500 in-lbs with a factor of safety of 1.5 or higher across the board. Using materials like Grade 5 Titanium and 7075-T6, our yokes are able to achieve max angles of 57 degrees. It also uses bonded carbon fiber shafts in order keep the weight of the entire shaft just under a pound.

half shaft closeup

Because we use a double-wishbone suspension, our shafts have to plunge inwards. We use ANSI B.92 Splines to achieve this while also transferring our torque requirement.

half shaft
half shaft

I also designed custom fixturing to bond these half-shafts in an oven to meet our torque transfer requirements.

Other Projects

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