Technical Questions & Answers

1. Stiffness vs Strength
Stiffness is the ability of a material to return back to its original form after being subjected to a
force.

Strength refers to how much stress a material can withstand before it fractures (UTS) or
permanently deforms (YS).

2. Resilience vs Toughness
Resilience refers to the ability of a solid material to absorb energy until elastic deformation. AKA
energy required to plastically deform. Resilience is an important property to consider when high
elastic deformation is desired, such as in springs.

Toughness refers to the ability of a solid material to absorb energy until it fractures. AKA energy
required to break. Toughness is an important property for metal forming processes (forging,
bending, sheet metal operations, etc.).
3. If there’s a coin on the desk, how many degrees of freedom does it have?
Degrees of freedom (DoF) refer to the number of basic ways a rigid
object can move through 3D space. There are six total degrees of
freedom. Three correspond to rotational movement around the x, y,
and z axes, commonly termed pitch, yaw, and roll. The other three
correspond to translational movement along those axes, which can be
thought of as moving forward or backward, moving left or right, and
moving up or down.

With that in mind, a coin on a desk will have 3 degrees of freedom as it can rotate about the
z-axis (going out of the desk). It can also move forward/backward as well as left/right.

4. Die Casting vs Injection Molding (High-Volume Manufacturing Methods)

The process of making a part is basically the

same whether you are using die casting or
injection molding. You create a die or mold in the
form of the part you want to create. You then
liquify the material and use extreme pressure to
inject it into the die/mold. You then cool the
die/mold with internal cooling lines and die spray
on the die cavities. Finally, you open the die and
remove the shot/part.

Although there are some variations in technique,

the major difference between die casting and
injection molding is that die casting uses some
kind of metal, often an aluminum alloy, as the raw
material, while injection molding uses plastic or
polymers.

* Note: The top image is the Die Casting Process,

whereas the bottom image is the Injection
Molding Process.

So why would you choose injection molding over die casting? If you are looking to produce a lot
of parts very inexpensively, injection molding might be the way to go, as labor and material costs
are fairly light, but it is important to keep in mind that tooling costs of the plastic injection
molding machines themselves and any secondary equipment can be fairly expensive.

If accuracy in design is a high priority, or you are looking to make many complex parts in a short
time frame, die casting is almost always the preferred option. Even if you are designing simpler
parts, many people prefer the obvious feeling of durability and quality you get in a solid metal
part over a plastic part. There’s also no need for secondary equipment when manufacturing a
part with Die Casting.

5. The Process of Die Casting

1. Before the steel mold is closed, it is sprayed with a lubricant. It regulates the temperature
inside the dies and facilitates easy removal of finished product at the end of the process.
2. Liquified metal is transferred into the die through extreme pressure, taking the form of
the die.
3. The mold is cooled by immersing or spraying it with cold water so that the casting can be
easily taken out.
4. The cast is removed by opening the die.

6. Injection Molding
The Process

1. Plastic Pellets are fed into the injection unit through a hopper
2. Screw rotates to transfer pelles forward, melting them in the process
3. Once at the front, pellets are entirely molten
4. Screw plunges forward, injecting molten plastic into the cavity image
5. Plastic solidifies → Mold Opens → Part is Ejected
6. Mold Closes → Repeat

From left to right, the components are: ram (1), screw (2), hopper (3), barrel (4), heaters (5),
materials (6), nozzle (7), mold (8), and part (9).

Helpful Video Animation: https://www.youtube.com/watch?v=b1U9W4iNDiQ

Common Defects

Defects Description How does this How to Prevent it?

defect occur?

Warping Occurs when certain parts cool Occurs with parts that Use a constant wall
faster than others. have non-constant thickness
wall thickness.
As a result, the parts that cooled
faster, shrink. This can result in
internal stresses, which can
cause permanent bends in a
part.

Sink Occurs when the surface of a Occurs with parts that Use a constant wall
Marks part cools slower than the have ribs that are thickness
interior. poorly designed
and/or parts with
This results in a sink mark in a thick walls
part that is supposed to be flat.

Drag These can occur during Occurs with parts that Add draft angles (a
Marks ejection. do not have a draft minimum of 2 degrees)
angle
As the walls of the part slide,
they can scrape against the
mold, resulting in drag marks

Knit The knit lines form when two Can occur in parts Increase material
Lines flows meet with holes or parts temperature, injection
with sudden speed or pressure*
They greatly reduce the geometry changes
aesthetics of a part Switch to a material
with lower melting
temp.or viscosity*

Short Occurs when there is trapped Can occur in parts Increase material
Shots air in the mold, which stops with very thin walls temperature, injection
material flow. speed or pressure*
 Redesign the mold with
wider channels or
gates for better flow

Add additional air vents

or enlarge existing
vents in the mold to
allow trapped air to
escape

Undercut They are items in the part being Occurs due to poor Move the parting line
manufactured that interfere with design such that it intersects
the removal of either half of the with the mold.
mold

* More on Knit Lines & Short Shots

● Increase material temperature: Higher temperatures on both materials prevent one
section from cooling too quickly.
● Increase injection speed and pressure: Faster-moving materials will meet more
quickly so one doesn’t cool too soon.
● Redesign the mold: Redesigning the mold to eliminate partitions between sections will
remove knit lines altogether.
● Switch materials: Materials with lower melting temperatures or viscosity allows for
faster flow and slower cooling.

Additional Defects can be found here: Injection Molding Defects and How to Prevent
- Includes: Flow lines, Burn Marks, Vacuum Voids/Air Pockets Weld lines, Jetting,
Discoloration, Delamination, Flash,

Injection Molding Tips

1. To prevent warping and sinking, use a constant wall thickness (1-3mm)

2. If a part requires thicker sections, then hollow out the thick sections and add ribs to
increase stiffness.
3. Certain parts require different wall thicknesses. For these parts, add smooth
transitions, such as a fillet or chamfer.
4. Round all edges to reduce stress concentrations at the corners. This will prevent the
part from becoming weak. For inner edges, it’s recommended to use a radius that is
 0.5*(wall thickness). For outer edges, it’s recommended to use a radius that is 1.5*(wall
thickness).
5. To make the ejection of a part easier and prevent any drag marks, add draft angles, a
minimum of 2 degrees.
6. If a part requires an undercut, then move the parting line such that it intersects with the
mold.
7. If the maximum wall thickness for a part is too small for the desired stiffness of the part,
then add ribs to achieve the desired stiffness.
8. Parting line should be perpendicular to text
9. Prototype your designs using 3D printing or CNC Machining.

Design Techniques

1. Use constant wall thickness (1-3 mm) à prevents warping and sinking
2. Hollow out thick sections, then add ribs to increase stiffness
3. Add smooth transitions (i.e. fillets, chamfers) for parts with multiple wall thicknesses
4. Round all edges to avoid stress concentrations
5. Add draft angles (min 2 degrees)
6. Move part line to intersect with undercut
7. Add ribs to increase stiffness, rather than increasing thickness

7. Ten Steps for a Smooth Transition to High Volume Manufacturing

1. Understand Your Production Quantities

Suppliers will generally require you to provide an estimated annual units quantity for first-run
production, so your plan for transitioning into high volumes should include estimates for first,
second, and third year units.

2. Research Your Manufacturing Options

Each method has unique advantages and disadvantages, and the best choice will depend on
your particular application.

3. Be Sure Your Product is Designed for High-Volume Manufacturing

For injection molded components, be sure that your 3D models are designed specifically for
moldability. This includes designing in proper draft angles which allow parts to be easily
removed from the tool after the plastic cools.

You’ll also need to ensure that you have designed plastic components with uniform wall
thicknesses. Regions with thicker walls will cool at a slower rate than regions with thinner walls,
which will cause the final part to warp or cause sink marks, which may have an adverse effect
on the aesthetics or functionality of the component.

Keep in mind that certain types of injection molded part features like undercuts or side-action
features add complexity to the mold tool and as such will add cost to your project.

4. Educate Yourself on the Manufacturing Processes Involved

Once you’ve narrowed down the manufacturing method that will be used to create your
component, ensure that you understand the method in detail.

Get acquainted with the typical manufacturing tolerances, process limitations, and industry
jargon. This will allow you to have more valuable conversations with vendors about your product
and allow you to ask the right questions about specific part features, materials, and
manufacturing processes involved.

5. Prepare to Engage Vendors with Prototypes and Existing Data

Nothing helps a vendor understand your product more quickly than existing prototypes. Vendors
may immediately be able to identify potential manufacturing problems with your design, or
suggest improvements, simply by having a prototype in-hand during an initial meeting.

6. Speak with Several Manufacturing Vendors About Your Product

If possible, consult with multiple vendors to get an idea of fair pricing and gather as much
feedback about your design as possible.

7. Build and Test Final Prototypes to Prevent Costly Tooling or Process Changes
As you transition into production quantities, you should have full confidence in the design of
your product.
Create final prototypes that represent the form and function of the final design as it will be when
manufactured at high volumes. In some cases for plastic components, vendors may be able to
provide high-quality prototypes using methods such as room temperature vulcanized molding
(often referred to as RTV or silicone molding) that will closely represent the final production part.
RTV molds can often be used for up to about 100 castings, and so may even be a good choice
for short-run production parts.

Changes to your hardware after tooling has been ordered or manufacturing processes have
been established will be incredibly more expensive than changes made during the design and
prototyping stages.

8. Include Your Industrial Design Resources in Discussions about Tooling

Keep in mind that high-volume manufacturing methods may have an affect on the final
appearance of your components, and so plan accordingly during the prototype phase.

For injection-molded parts, witness lines at the mold split and ejector pin locations will impact
part aesthetics and may require slight modifications to the contours or external features.

Also, as mentioned earlier, sections where wall thicknesses are greater, such as areas where
ribs or bosses are used, may have sink-marks. Ask your vendor about surface finishes that can
be applied to the mold to disguise these issues.

9. Understand the Concept of “Steel Safe” Design

When specifying tolerances and dimensioning features on injection molded components,
remember the idea “maximize steel, minimize plastic.” It’s possible to make walls thicker,
take away holes, and add features like bosses or ribs to a plastic design by modifying an
existing mold, but it’s impossible to make walls thinner, add holes, or take away raised
features without creating a new tool.

10. Implement Business Processes For High Volumes of Product

Taking the leap to full-scale production is a significant milestone. By testing functional
prototypes, educating myself about the manufacturing processes involved, and creating a
flexible plan for moving forward, you’ll be positioned to make confident decisions that will
maximize your opportunity for success.
8. How do you handle a fast-paced environment?

I’ve had past work experience working in fast-paced environments since I’ve spent a lot of time
working with several start-ups that move really quickly. From these experiences, I’ve learned to
handle fast-paced environments by:

1. Educating myself on my role by talking to my manager about any training material I can
read up on before my first day.
○ For example, although I understand many of the terms and abbreviations in the
engineering field, I make sure to ask if there are terms or abbreviations that are
specific to the company and their unique processes.

2. Make sure to pay attention to minor details as well as organize and track my work. I’ll
always create GANTT charts for all the projects I’m working on. This chart will include
how long I’ve been working on a project, any issues I’ve been having with it, potential
risks and how I can mitigate them as well as when I expect to complete it.

3. Break massive projects into smaller tasks that are easier to manage.

4. Batch my work. Once I’ve broken down my projects into smaller, more manageable
tasks, I’ll batch similar tasks and work on them together. This just helps me be more
efficient and manage my time better which is very important in fast-paced environments.

Example: Centrifuge Tube Reader I worked on at Validere

9. CATIA vs SolidWorks
- Solidworks is designed particularly for 3D solid objects modeling, whereas CATIA has
more sophisticated and versatile tools for drawing, modeling, and sketching.
- Specifically, CATIA’s extra smooth 3D rendering and Photo-to-Shape app, which
creates immersive 3D models from 2D photographs
10. DVP&R

What is it?
A tool that documents the plan that will be used to confirm that a product, system or component
meets its design specifications and performance requirements. Each of the design
specifications or product requirements are documented in the DVP&R form along with the
analysis or test used to determine if the specification or requirement has been met.

The DFMEA determines “What” and the DVP&R defines “How”.

- The Whats are the list of analysis and verification tests developed during the FMEA
activity.
- The Hows are the methods of testing or how the analysis or test will be performed,
including the acceptance criteria and the report of the results.

Why use it?

It allows for complete and concise documentation of the analysis and verification activities
completed during a new product introduction, design change or product recertification.

The DVP&R presents a clear picture understandable by the sponsor, stakeholders and team
members, allowing all to understand the status of the analysis and verification testing.

It is also a very useful tool to use during any quality issue investigation during the life of the
product.
11. DFMEA
12. Resonance

Resonance occurs when you apply a forced vibration on an object, where the frequency of the
forced vibration is equal to the natural frequency of the object. This results in a vibration with a
large amplitude.

The natural frequency of a system is dependent upon two main factors; stiffness (k), and mass
(m). Typically, the objective is to increase the natural frequency such that it is above any
expected vibration frequencies. If the natural frequency is above or significantly far away from
any expected vibration frequencies, the resonance will likely not occur. This theory forms the
basis for any structural redesigns implemented to avoid resonance.

So, to minimize vibration response of a system:

1. Adding stiffness increases the natural frequency

2. Adding mass decreases the natural frequency
3. Increasing damping reduces the peak response
but widens the response range
4. Decreasing damping increases the peak
response but narrows the response range
5. Reducing forcing amplitudes reduces response
at resonance
Tesla Questions - Rough Outline
1. What is your specific experience with CATIA? To what extent have you used it and
where? (its ok if you haven’t used it, be ready to talk what CAD tool you’ve used and
what products you’ve designed)

2. They will test your knowledge on basic engineering fundamentals (I would brush up on
possible calculations/questions from the FE exam: fundamentals of engineering exam)
(also any type of calculations you’ve had to do in your current role)

3. Be prepared for critical thinking questions as well

4. Walk me through a design that you have owned?

5. Be ready to explain material properties (ex: what is stiffer, steel or aluminum?)

6. What is the difference between stiffness vs strength? (be prepared for questions on this)

7. Do you have any experience with validation/testing?

8. Knowledge on how something is made: how to make things at volume, how high volume
products are made, design criteria for high volume

9. Difference between Resilience and Toughness

10. Distinguish between "Stiffness vs Strength"

11. If there is a coin on top of a desk, how many degrees of freedom will the coin have?"
(the answer should be 3 and you need to explain why it is 3, the 3rd degree is the
rotational degree, which is commonly forgotten)

12. The hiring manager will walk through your resume and different experiences (be
prepared to speak heavily on your resume)

13. How do you handle a fast paced environment? Tesla is looking for someone excited and
adaptable to handle that type of fast paced environments. Provide examples of any
types of deadlines you have had to meet and how you would go about doing that.

14. What is your experience dealing with suppliers?

15. If the manager were to give you a designing task using CATIA would you need help or
would you be able to handle that on your own? (he is looking for people who are
comfortable with CATIA).
 16. He is going to ask about your experience/knowledge on plastic injection molding. (be
ready to talk through the injection molding design process, where you have done it, what
your knowledge is on that or any manufacturing processes)

17. He is going to talk with you about the role, get your input on the role, and see if you feel
like you could handle the role. (be positive and excited about the project and let him
know you would be able to handle the role)

MDE Questions
1. Experience with CAD software? (ex. SolidWorks and CATIA)
2. Walk me through a designed u owned
3. Explain material properties
a. Stiffness between Steel and Aluminum
b. Stiffness vs Strength
c. Resilience vs Toughness
4. High Volume manufacturing methods
a. Injection Molding vs Casting
5. If there’s a coin on the desk, how many degrees of freedom does it have? Three
(including rotation)
6. What’s your experience in injection molding?
a. How does the process work?

*Walk through the resume*

When talking to Managers, immediately start walking through the work and projects after they
ask u questions. “Yes, I’ve done it. Here’s an example”

TPM Questions
1. During your student design project, did you ever use the GANTT chart?
a. How often did you use it?
2. Structure Parameters to increase efficiency
a. Mass, shape, stiffness, cross-sectional area, moment of area
3. Draw a stress-strain curve for Steel/Aluminum

*add the use of GANTT chart and dealing with multiple projects at once in resume*
Classic Job Description

• Design of automotive component parts in CATIA V5.

• Develop and execute interior system requirements for one or more of the aforementioned
interior commodities.
• Participate in the iterative process with the Tesla design/styling studio to deliver the optimal
balance of form vs. function vs. cost
• Implement processes and material selections to achieve world class execution of automotive
interior craftsmanship and fit & finish.
• Optimize designs with the appropriate analytical and physical assessments.
• Complete and release interior components, sub-system and detail designs, utilizing a mix of
in-house design and supplier engineering where required (in-house designs are planned for
most major commodities).
• Utilize DFSS methodologies as appropriate during the design, validation and launch of the
program
• Interpret CAE simulation results and integrate recommendations into product design.
• Collaborate with key exterior system and plastic component suppliers and support overall
vehicle development milestones and prototype/production build events.
• Collaborate with cross-functional teams within the Tesla Vehicle Engineering, Manufacturing
Engineering and Procurement groups to ensure exterior system manufacturing and assembly
feasibility and serviceability.
• Responsible for technical documentation to include DFMEAs, DVP&R’s.