Proven results at scale
From Tesla's highest-volume platforms to robotics startups, the methodology works.
Tesla — $50M+ in annual savings
Platforms
Model S, 3, X, Y, Cybertruck, Cybercab
Vehicles per year
Annualized savings
Faster than industry standard
Cybertruck & Cybercab
thermal system cost reduction
Simplified core coolant architecture from 21 to 10 parts while expanding scope and function.
Model 3 & Y
coolant system cost reduction
Designed a connector with 40% higher flow efficiency at 2/3 the cost, saving $5M+/yr.
Model S & X
system cost reduction
- Pioneered "smooth" tubing approach
- Contributed to Tesla's patent-pending Dual Connector
- Subject matter expert on coolant hoses
- Defined company-wide guidelines and test standards
- Mentored new employees, grew team from 2 to 6
Lionsbot — Concept to mass production
Redesigned chassis, suspension, water pump, and motor subsystems for their latest autonomous cleaning robot. Goal: optimize for mass manufacturing at lower cost on an aggressive timeline.
"Ethan was essential in bringing our chassis and robot systems from concept to mass manufacture this year. He seamlessly integrated with our Singaporean workforce, quickly grasped our systems, and leveraged his Tesla experience to become an indispensable team member."
Redesigned suspension balancing cost with reliability
Chassis assembly using laser-cut weldments and corrosion coatings
Consolidated subsystem mounting while lowering tooling costs
DFM reviews and poke-yoke implementation on the manufacturing line
FEA simulations and custom corrosion/vibration test infrastructure
Supplier transitions for bushings and shock absorbers