Hayden Wolfe

Experience

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  Lockheed Martin

  Sept 2018 - May 2019

  Engineering Explorer's Post

  Learned about mechanical & aerospace engineering and design through a combination of weekly lectures and hands-on projects and challenges.

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  Where There Be Dragons

  Jun 2019 - Jul 2019

  English Second Language Teacher

  • Created activity-focused lesson plans to teach English to Chinese secondary school students• Taught students for 8 hours every weekday, using collaborative, engaging, and out-of-the-box methods• Guided a Chinese college student in crafting a high-quality resumé for US job applications, resulting in offers

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  Outdoor Odyssey

  Oct 2020 - Aug 2022

  Wilderness Guide

  • Planned and led outdoor trips (6-day climbing and backpacking) for incoming Cornell students• Collaborated with co-instructors to teach outdoor survival techniques and wilderness safety• Facilitated a welcoming atmosphere to encourage students to challenge themselves and explore outdoors

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  Cornell Racing (FSAE)

  Nov 2020 - Dec 2024

  • Increased torque at wheels by 39% (276 Nm) through optimization of final drive ratio (FDR)• Designed a compact and robust 2-stage compound planetary gearbox for in-hub electric motors• Learned key design parameters for gear design and optimize for reliability, torque, and speed • Design all fixtures for CNC machined components• Consult manufacturability of all machined components• Schedule manufacturing of machined components to ensure completion of car by expected date • Spearheaded a 38% reduction in Design time (4 to 2.5 months), by prioritizing key performance variables• Lead weekly team meetings, providing technical guidance and consultation on parts and system designs• Monitor and report progress frequently, using color-coded indicators for the stage of each component• Redesigned wheel hub and upright assembly, reducing mass by 5.4% using smaller bearings • Improved braking by increasing COF, utilizing ANSYS thermal and structural FEA to obtain more optimal steady state temperature, by adjusting materials (thermal conductivity), thickness, and diameter

  • Planetary Gearbox Design Engineer

    May 2024 - Dec 2024

  • Manufacturing Lead

    May 2023 - May 2024

  • Unsprung Team Leader

    May 2022 - May 2023

  • Unsprung Team Member

    Nov 2020 - May 2022
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  Action Karting

  May 2021 - Aug 2021

  Kart Mechanic

  • Diagnosed and repaired racing-series karts, inspecting ignition coils and spark plugs, dismantling engine• Developed mechanical assembly and Design for Serviceability skills, reducing repair Cycle Time• Improved Availability of karts, by increasing efficiency and effectiveness with standard workshop tools

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  Cornell Outdoor Education

  Aug 2021 - Dec 2024

  Climbing Instructor

  • Instruct Cornell students, faculty, and staff in intermediate rock and ice climbing techniques• Guide the development of problem-solving skills, perseverance, and physical fitness• Collaborate with other instructors to design more effective and entertaining lessons

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  Emerson Machine Shop

  Feb 2023 - Dec 2024

  Manufacturing & Fabrication Instructor

  • Instruct Cornell Engineering students in safe and efficient use of manual mills, lathes, and machines• Coordinated with other staff to cut average training times from 5 to 4 hours through optimization

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  SpaceX

  May 2023 - Aug 2023

  Mechanical Engineering Intern

  • Designed modular stacking tray system to eliminate production bottleneck & raise throughput by 200%• Created and performed laser welding DOEs & utilized RCA to improve process yield from 75% to 100%• Designed 4 sets of 3D-printed tools in one workday to eliminate touching critically clean part surfaces• Routinely communicated with supply chain to secure quickest, most efficient supplying solutions• Quickly and creatively developed iterations of designs, being detail oriented and dedicating overtime• Delivered 75-minute presentation to upper-level management showcasing 6 completed projects Show less

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  SpaceX

  May 2024 - Aug 2024

  Graduate Engineer
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  Sierra Space

  Feb 2025 - now

  Tooling Engineer