Zakariae Z.

End-to-end design and validation of a direct-drive steer-by-wire actuator (A-sample), integrating a high-resolution (16-bit) torque & angle sensor (TAS) and redundant Vernier angle measurement; reduction of cogging torque to under 10 mNm, 30% increase in MRF brake torque density with response time < 10 ms, and 25% improvement in low-speed/high-torque efficiency.

Design of a high-voltage contactor from CAD to A-sample, using FEA to increase prototype stiffness by 44% and characterize thermal behavior; execution of D-FMEA and DOE sprints to mitigate four high-severity risks; management of the test plan, supplier sourcing, and DFM/DFA to deliver A-samples on time, ready for B-sample industrialization (pre-PPAP).

• Lighting – Project Management (Opel Light Compass):

o RFI/RFQ management, then upon nomination, CAD/FEA design (vibration/thermal/optical), +35% stiffness, UTAC compliance, +45% FOV, de-risking of B-sample homologation, FTO.

• Autonomous Tailgate:

o System architecture (ECU/actuator/sensors/harnesses), safety, integration of rotational radars, NVH mounts/sealing.

• Active Aerodynamics:

o End-to-end architecture, CAN/LIN & diagnostics, kinematics/actuation, CFD for drag maximization during braking.