Sean Sullivan

Experience

• 

  St. Louis University, Formula Student Team

  May 2006 - May 2009

  Student Designer

  Headed the design efforts of the 2008/2009 racecar; this included the car’s innovative rotary damper suspension.

• 

  Star Manufacturing

  May 2007 - Aug 2007

  Engineering Intern

  Scrutinized and modified illustrations for user manuals and constructed bills of materials as well as engineering drawings.

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  DoTec Engineering

  Dec 2007 - Jan 2008

  Engineering Intern

  Researched and presented concepts for sealing a medical device to protect the sensitive electronics from environmental contaminants.

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  LMI Aerospace

  Nov 2009 - Jan 2012

  Contract Engineer

  Developed conceptual designs for CNC-mill tool fixtures based on CAD models of Boeing 777 production components. Interpreted blueprints and reversed engineered CAD models from original drawings based on customer specifications. Communicated with various disciplines within the company to create manufacturing estimates and coordinate the efforts of subcontractors. Created assembly and part drawings using principles of GD&T. Programmed MasterCAM CNC tool paths for production aerospace components.

• 

  Atech Reid GP

  Feb 2011 - Sept 2011

  Thesis Project

  Determined optimal race setups for the Formula Renault race cars using laptime simulation and advanced dynamic modeling software. This project required risk management and in depth research. All of the results were reported to the engineering team at Atech Reid GP.

• 

  Bryan Herta Autosport

  Jan 2012 - Feb 2013

  Damper Engineer

  Responsible for the development and application of the mechanical inerter-damper hybrid suspension system. Used simulation and track data to develop the optimal race setup for the damping system. Performed detailed failure analysis on early generation components and oversaw the implementation of updated designs.

• 

  Andretti Autosport

  May 2013 - Mar 2014

  Contributed to the advancement of the Indycar suspension system by developing unique data analysis procedures, performing complex vehicle dynamics modeling, and producing new software tools using Matlab/Simulink. Maintained and repaired the Cosworth Electronics data system, sensors, and telemetry network for the 26 car of Carlos Munoz during the 2013 Indy 500 event.

  • Damper Engineer

    Feb 2013 - Mar 2014

  • Data Acquisition Engineer

    May 2013 - May 2013
• 

  Roush Fenway Racing

  Mar 2014 - Dec 2016

  Design and implement complex custom microcontroller systems for use on test cars. Create a unique data acquisition network for use on pit stop equipment. This includes the hardware design, sensor layout, software interface, and data processing. Expand the efforts of the research and development department by assisting the 8-post testing program. This includes generating new techniques for analyzing the test results, creating new test methods, and studying chassis designs using experimental modal analysis. Other responsibilities involve constructing mathematical models using Matlab/Simulink and designing custom components for the damping system.

  • Electronics Engineer

    May 2016 - Dec 2016

  • Vehicle Dynamics Engineer

    Mar 2014 - May 2016
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  Pratt & Miller Engineering

  Jan 2017 - Feb 2019

  Vehicle Dynamics Simulation Engineer

  Support the Chevrolet NASCAR program by improving existing features and creating new components in the full-vehicle Modelica model using Dymola. Help race teams make best use of their driver-in-the-loop sessions by analyzing data, pre-testing models, and troubleshooting issues with the simulator.

• 

  Husqvarna Group

  Apr 2019 - Apr 2020

  Electrical Test Engineer

  Created and executed test plans for new and existing electrical products including battery handheld tools, battery ride-on mowers, and IoT based subsystems. Common tasks included developing custom electro-mechanical test systems, sensor selection, instrumenting test units, data analysis, failure analysis, and writing detailed test reports.

• 

  TTI Floor Care North America

  Oct 2020 - May 2024

  • Senior Robotics Test Engineer

    Jul 2022 - May 2024

  • Senior Electronics Test Engineer

    Oct 2020 - Jul 2022
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  Bosch USA

  Jun 2024 - now

  Motorsports Customer Application Engineer