Engineering Portfolio

Will Santana

Berkeley FASE

I’m a member of UC Berkeley’s Formula SAE team, where students design, manufacture, and race a small-scale formula-style car each year. As part of the Suspension subteam, I contribute to both design and fabrication, focusing on precision, reliability, and serviceability.

Steering Rack

I contributed to the design and packaging of the steering rack assembly for Berkeley FASE’s 2025 race car. The goal was to improve steering precision while maintaining serviceability and compliance with chassis constraints.

I modeled the rack housing, mounts, and tie rod interfaces in SolidWorks, ensuring proper alignment with the steering column and suspension geometry. I developed detailed manufacturing drawings using GD&T standards to define tolerances for bearings, seals, and mounting holes.

The updated design reduced play in the steering system and improved ease of maintenance during vehicle assembly. I also supported the machining and fit-up process, confirming that clearances matched expected tolerances.

Recommend visiting my presentation linked in the image.

Tools: SolidWorks,

Shock Dyno

I designed and built a dyno for suspension testing and tuning on the Formula SAE team. The goal was to create a compact, repeatable system for measuring damper performance under controlled conditions.

I led the design of a custom welding jig and sensor mounts, ensuring alignment between the actuator, damper, and load cell. The system integrates a FUTEK load cell for force measurement and uses a Python-based workflow for data collection and analysis.

Throughout the project, I focused on simplifying setup time, improving fixture rigidity, and increasing repeatability between test cycles. This tool now supports the team’s damper characterization and validation process, helping refine vehicle handling and ride quality.

Tools: SolidWorks, FUTEK, MATLAB, Python, Shop Tools

Welding Jigs and Fixtures

Description:
I developed several welding jigs and fixtures to support precise chassis and subassembly fabrication for the Formula SAE car. These jigs ensure consistent geometry and repeatable positioning during welding, reducing assembly time and minimizing post-weld alignment errors.

I modeled the fixtures in SolidWorks, incorporating locators, clamps, and datum points for key frame tubes and bracket interfaces. I validated each design for accessibility, weld sequence, and stack-up tolerance. Once finalized, I assisted with manufacturing and verified alignment on the welding table.

This work improved assembly accuracy across multiple subteams and provided documentation for future fabrication cycles.

Tools: SolidWorks, Mill, Bandsaw, Welding Table, Measurement Tools

MotoStudent

I was a part of the MotoStudent Engineering Team, a student-led project that designs, builds, and races a fully functional motorcycle for international competition. The team combines mechanical design, manufacturing, and testing to create a lightweight, high-performance prototype that follows real-world engineering standards.

I’ve contributed primarily to the rear suspension and drivetrain subteam, focusing on swing arm geometry, linkage design, and brake system integration. My work emphasizes manufacturability, structural efficiency, and precise fitment between components designed by multiple subteams.

Through MotoStudent, I’ve gained experience in collaborative CAD design, tolerance planning, and system integration, working alongside peers to bring a full-scale vehicle from concept to fabrication.

Swing Arm Design

I contributed to the rear swing arm design for our MotoStudent race motorcycle. The objective was to define a geometry that balanced stiffness, weight, and packaging around the rear wheel, chain line, and suspension system.

Using SolidWorks, I positioned the swing arm pivot, axle, and shock mount points to meet wheelbase and anti-squat targets defined by the chassis team. I also performed motion and clearance checks with the rear tire, chain, and brake system to ensure serviceability and alignment.

This work laid the foundation for finite element analysis and future fabrication. I focused on making the design manufacturable using standard aluminum tubing and welded joints, allowing for later weight optimization and stiffness tuning.

Tools: SolidWorks, FEA Setup, Chassis Geometry

Link and Rocker Design

I designed and analyzed the rear suspension linkage system for the MotoStudent motorcycle, which connects the swing arm to the rear shock. The goal was to achieve a smooth and predictable motion ratio while maintaining clearance and minimizing weight.

Using SolidWorks, I developed multiple iterations of the link and rocker geometry to refine leverage curves and optimize suspension travel. I ensured that all components maintained proper alignment with the chassis mounting points and verified that no interference occurred throughout the shock’s stroke.

The design also considered serviceability and manufacturability, using standard hardware and bearing sizes to simplify assembly. The final geometry provided a strong baseline for future finite element analysis and physical testing.

Tools: SolidWorks, Kinematic Simulation, CAD Assemblies

Rear Sprocket Design

I led the design of the rear sprocket and hub interface for the MotoStudent race bike. The objective was to ensure proper chain alignment, fitment to the rear hub, and reliable torque transfer under load while maintaining a lightweight structure.

Using SolidWorks, I modeled the sprocket with precise pitch, tooth count, and bolt circle dimensions to match the selected chain and hub assembly. I validated the design for concentricity, clearance to the swing arm, and machining feasibility.

I also created a detailed manufacturing drawing with callouts for tolerances, chamfers, and surface finish, ensuring compatibility with standard sprocket vendors. The design integrates seamlessly into the drivetrain and supports efficient power delivery during testing.

Tools: SolidWorks, Machining Drawings, Chain Geometry

Rear Brakes

I developed a rear brake caliper mounting concept for the MotoStudent motorcycle to ensure precise rotor alignment and secure braking performance. The design focused on achieving an optimal balance between stiffness, weight, and serviceability within the tight constraints of the swing arm assembly.

Referencing geometry from the 2014 KTM RC 250 R platform, I modeled the caliper bracket, rotor spacing, and fastener layout in SolidWorks. I ensured proper clearance between the rotor, caliper body, and wheel hub while maintaining alignment with the swing arm’s axle path.

The final bracket design simplified manufacturing using standard machining operations and provided easy access for maintenance and pad replacement. This layout will serve as the foundation for future brake performance validation and testing.

Tools: SolidWorks, Machining Design, CAD Fitment Checks

Wind Turbine Project

For my introductory mechanical design course at UC Berkeley, I worked in a small team to design, 3D-print, and test a functional wind turbine prototype. The project focused on aerodynamics, design for manufacturing, and system efficiency.

I modeled the blades, hub, and housing in SolidWorks, optimizing the blade profile for consistent rotation under low wind speed conditions. I adjusted the hub geometry for proper balance and reduced print time by re-parameterizing support angles and wall thickness.

The finished turbine successfully generated measurable output during lab testing. This project strengthened my understanding of design iteration, printing tolerances, and performance testing with low-cost components.

Tools: SolidWorks, 3D Printing, Basic Instrumentation

Sustainable Energy Prototype

In my senior-year engineering capstone project, I led a small team to design and build a low-cost sustainable energy prototype focused on accessibility and real-world impact. The goal was to create a system that could demonstrate clean energy generation using locally available materials.

I managed the full design process, from early sketches to final construction and testing. Our team used CAD modeling to plan the layout, sourced thrifted and recycled components to stay within budget, and documented all performance results for presentation.

The prototype achieved consistent energy output under variable load conditions and served as an educational tool for demonstrating renewable energy principles. This project helped me refine leadership skills and apply mechanical design to community-based problem solving.

Tools: SolidWorks, Basic Electronics, Project Management

SDSU Camacho Lab

At San Diego State University, I worked under Professor Joaquin Camacho supporting experimental research on flame synthesis and combustion materials. My role combined hands-on lab assistance with digital design work for the lab’s online presence and outreach.

I helped set up and maintain experimental equipment for soot characterization and material synthesis while following safety and calibration standards. Alongside lab work, I designed and launched the group’s academic website, showcasing publications, research focus areas, and personnel.

This experience exposed me to the structure of an academic research environment and improved my technical communication, attention to procedure, and ability to translate engineering work into accessible visuals for broader audiences.

Tools: Lab Equipment, HTML/CSS, GitHub Pages, Adobe Illustrator

SDSU Dr. Adibi Lab

Under Professor Sara Adibi at San Diego State University, I contributed to computational mechanics research focused on aerospace materials and thermoplastic composites. My work supported both numerical simulation and technical proposal development for NASA and DoD applications.

I assisted in setting up and running molecular dynamics simulations using LAMMPS to study high-temperature polymer behavior and interface strength under load. I analyzed simulation data using Python and helped generate figures for manuscripts and reports.

In addition to research tasks, I played a key role in proposal preparation, including literature reviews, technical editing, and figure design for NASA’s MPLAN challenge and DoD SBIR Phase I submissions. This experience strengthened my ability to connect computational modeling with real engineering objectives and mission needs.

Tools: LAMMPS, Python, LaTeX, ANSYS Fluent, Microsoft Office

Summary

My engineering work blends hands-on design, research, and system integration. Whether building testing equipment for Formula SAE, designing suspension systems for MotoStudent, or contributing to computational research at SDSU, I focus on solving real mechanical challenges through collaboration and precision.

Each project on this page represents a stage in my growth as an engineer—moving from CAD design and fabrication to simulation, testing, and proposal development. I value projects that connect technical work with real-world application, and I continue to pursue opportunities that combine design, analysis, and innovation.

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