David Lu

Mechanical Engineer | Design, Analysis, Manufacturing | University of Michigan

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daviddw@umich.edu • 734-277-2385 • www.linkedin.com/in/dwdavidlu

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MRover

2024-2025 Video

2023-2024 Video

Chassis Lead - Chassis Optimization (Current)

Problem: New sheet metal chassis redesign for novelty and mass-saving.

Tools: Ansys, Siemens NX.�Actions:

• Designed and created new system architecture for chassis subsystem
• Tested and measured different load cases
• Verified system against multiple different load cases using FEA
• Used FEA results to iterate design to optimize for mass while maintaining structural rigidity

Results: New verified sheet metal chassis ~1 kg lighter than previous year

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See my Critical Design Review for further detail: CM CDR 2025-2026

See my Critical Design Review for further detail: CM CDR 2025-2026

System Architecture

• Frame
• Differential Bar
• Mast
• Mast Gimbal
• GPS Wings
• Battery

Frame

Battery

Differential Bar

Mast

Mast Gimbal

GPS Wings

Testing

Straight Drop Test

Frontal Impact Test

Uneven Platform Drop Test

Platform Drop Test

Straight Drop Test FEA

Max Von Mises Stress: 122.41 MPa

Stress Safety Factor (Yield): 1.58

Max Displacement: 1.37 mm

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*Applied force values obtained from drop and impact testing with accelerometers

**This is the 11th iteration of design and FEA

32x True Scale

Frontal Impact FEA

Max Von Mises Stress: 40.35 MPa

Stress Safety Factor (Yield): 4.78

Max Displacement: 0.11 mm

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380x True Scale

Science Payload Impenetrable Ground FEA

Max Von Mises Stress: 41.51 MPa

Stress Safety Factor (Yield): 4.65

Max Displacement: 0.199 mm

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200x True Scale

Robotic Arm Fully Extended FEA

Max Von Mises Stress: 23.28 MPa

Stress Safety Factor (Yield): 8.29

Max Displacement: 0.037 mm

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1100x True Scale

Suspension Optimization

Problem: Rover suspension was overweight and limited terrain performance.

Tools: Ansys, Siemens NX, Mill.�Actions:

• Ran FEA & topology optimization → 30% mass reduction.
• Designed & manufactured suspension plates.

Results: Improved terrain mobility & ensured structural integrity

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Suspension Optimization

No Weight-saving

Topology Optimization

Manual redesign for aesthetics and manufacturability

Executive Board Treasurer - MRover

Problem: $70,000+ annual budget across 20 subteams.

Actions: Coordinated 500+ purchases, automated expense tracking in Google Sheets.

Results: Enabled 9th/100+ URC finish, 2nd/20+ CIRC finish.

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Semi-automated Budget Dashboard

Fixture Design & Process Optimization - Brooks Utility Products

Problem: High assembly cycle time & inconsistent processes.

Role: Manufacturing Engineering Intern.

Actions:

• Designed SolidWorks fixtures, optimized assembly workflow.
• Applied Lean Six Sigma & value stream analysis → 20% cost reduction.

Results: Reduced cycle time 25%, inventory time 20%.

3D Printed Fixture Prototype

ME 450 - Design and Manufacturing III Capstone Project

Problem: Design a lighter, easy to assemble, and structurally-sound blended-wing fuselage for M-Fly’s competition this year. It must allow for detachable wings and tail booms and be able to be built with student friendly processes.

Actions:

• Performed FEA analysis in Ansys to verify structural integrity and iterated design for weight-saving
• Researched composite material properties for FEA
• Designed components in Siemens NX
• Coordinated with teammates

Ribs

Shear web

Shell

Hatches

Tail boom joint

Wing joint

Spars

First Iteration

Final Iteration (added weight-saving cutouts)

Second Iteration (extended wing spar into third rib to reduce stress and added tail boom design

*Loads applied are worst-case 9g dive pullout loads

Setup

ME 350 - Design and Manufacturing II Project

Problem: Design and manufacture a linkage mechanism to shine light on randomly activated targets

Actions:

• Performed linkage analysis to optimize transmission angle, weight, and speed
• Designed components in SolidWorks
• Coordinated with teammates
• Manufactured using mill, lathe, waterjet
• Wrote code to program mechanism

Results: 27 out of 31 possible targets hit; A+ in the class

Linkage Mechanism Video

ME 250 - Design and Manufacturing Project

Problem: Design and manufacture a robotic machine player (RMP) to compete in annual competitions

Actions:

• Designed components in SolidWorks
• Coordinated with teammates
• Manufactured using mill, lathe, waterjet, 3D printing

Results: 1st place at annual design expo competition

RMP Hype Video