Hoyt St. Urban Assault Vehicle

Initially as an independent contractor, I worked in conjunction with the Chief Engineer to design and build several prototype battery packs to their specification. 

The battery layout was particularly challenging because of the unique structure of Hoyt skateboards. Their boards used a formed bamboo enclosure on the underside of the skateboard deck. 

Due to the limitations of the bamboo forming process, this resulted in an unusual battery layout which was challenging and labor intensive to produce on a prototype basis.

Immediately identifying the challenges with this battery layout, I adapted the battery layout to a PCB system. 

Using CAD, I designed custom nickel spot-welding tabs for mass manufacturing and sourced them from an international supplier. 

I designed and 3D-printed critical components of the battery system, allowing the completed battery pack to integrate seamlessly into the electric skateboard.

These PCB battery systems greatly reduced assembly labor, while producing a more robust and reliable battery pack. 

Shortly after I was contracted, I was offered a full time position at Hoyt as their Electrical Design Lead. 

In this role, I designed and directed the manufacturing of all battery packs in house.

The optimizations I brought to their battery manufacturing allowed Hoyt to employ American labor to build their batteries, at a rate competitive to what they were quoted from overseas battery manufacturers and at a much higher quality.