Summary
Overview
Work History
Education
Skills
Timeline
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Mike Cesarano

San Diego

Summary

Creative problem-solver with a strong foundation in core engineering principles, adept at turning complex challenges into practical, innovative solutions. Known for combining technical expertise with out-of-the-box thinking to deliver results that are both effective and efficient.

Overview

16
16
years of professional experience

Work History

Tesla - Cell Manufacturing
San Diego
04.2021 - Current
  • Designs cell formation and cell test equipment using electro-thermal analysis (joule heating), tolerance stack analysis, stress-strain analysis, FEA simulation (Ansys), and 3D CAD software (SolidWorks/CATIA).
  • Completely designs automated mechanical systems that integrate cameras, sensors, and actuators, with custom mechanical hardware.
  • Creates electronics packaging solutions including: fastening, thermal management, connector application, bus-bar design, and cable routing.
  • Designs custom heat exchange equipment for temperature control of electrical test equipment.
  • Led a 14 person cross-functional team of mechanical, electrical, firmware and software engineers through multi-year program to develop custom cell cycling test equipment to support characterization of 4680 battery cells. To date, 10,000 150-amp cell test channels have been deployed, resulting in a $40 million savings to Tesla over vendor-supplied channels.
  • Personally designed a 1800A DC/AC converting cabinet and modular DC Bus system to deliver power and enable power sharing to cell cycler rows and reduce overall DCAC conversion needs.
  • Designed a novel, compensating material handling tool to more precisely pick and place battery cells in cell formation.
  • Solved a cell test overheating problem by reducing joule heating losses in a creative way. This solution unlocked an 55% increase in cell charge current capability within existing equipment.
  • Utilizes FMEA methodology to ensure robust designs.
  • Uses GD&T to create clear, detailed part drawings.
  • Uses DFA/DFM to design parts manufactured by machining, sheet metal, injection molding, and extrusion.
  • Employs rapid prototyping techniques to test design elements to reduce technical risk.

Staff Equipment Engineer

Tesla - Machining and Castings
Lathrop
12.2018 - 04.2021

Equipment Engineer

Tesla - Machining and Castings
Lathrop
10.2015 - 12.2018
  • Designed and integrated automated equipment and robotic work cells as part of an in-house factory automation team. Managed these projects from conception through handover to process and production.
  • Created Fanuc and Kuka robot programs for welding, packaging, pick and place, fastener installation and quality inspection applications.
  • Specified and designed for: actuators, motors, linear guides and bearings, sensors, conveyors, cameras and other machine components.
  • Used SolidWorks to design custom parts, tooling includes robotic welding fixtures, robot end of arm tooling, fastening tools, laser part marking systems, lift assists, and quality control devices.
  • Created and supported several automated inspection systems to detect the presence or absence of operator-installed components on extrusion parts.
  • Developed upgrades and retrofits to existing equipment to improve up-time and add capability.
  • Supported maintenance by troubleshooting equipment breakdowns.
  • Used metal fabrication skills to repair equipment.
  • Provided drawing packages and maintenance instructions for custom equipment.

Mechanical Engineer GS-13 Civ.

SISCAL- NAVSEA – US Navy
Philadelphia
08.2009 - 09.2015
  • Designed, edited, tested, and implemented calibration procedures to be used on naval shipboard equipment.
  • Led teams of 6-8 technicians during calibration sweeps of over 80 Naval ships.
  • Developed calibration requirements list (CRL) for new construction ships.

Education

M.S. - Mechanical Engineering, Mechatronic And Robotic Systems

University of Pennsylvania
Philadelphia, PA
07.2015

B.S. - Mechanical Engineering

Rutgers University
New Brunswick, NJ
05.2009

Skills

  • Machine Design
  • 3D CAD: SolidWorks (inc PDM), CATIA 3DX
  • Fluid Power System Design
  • Robot Programming (Fanuc, Kuka)
  • 2D/3D Machine Vision Programming
  • Tolerance stack analysis
  • GD&T
  • Rapid Prototyping
  • CNC Machining and programming (HAAS VF2)
  • Shop Tools: Mill, Lathe, Ironworker, Brake
  • Welding MIG/MAG, TIG
  • Microcontroller programming (Arduino, AVR-C)
  • Design for Manufacturing/Assembly (DFM/DFA)
  • FEA for structural and thermal analysis: ANSYS

Timeline

Tesla - Cell Manufacturing
04.2021 - Current

Staff Equipment Engineer

Tesla - Machining and Castings
12.2018 - 04.2021

Equipment Engineer

Tesla - Machining and Castings
10.2015 - 12.2018

Mechanical Engineer GS-13 Civ.

SISCAL- NAVSEA – US Navy
08.2009 - 09.2015

M.S. - Mechanical Engineering, Mechatronic And Robotic Systems

University of Pennsylvania

B.S. - Mechanical Engineering

Rutgers University

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Mike Cesarano