Head of Additive Manufacturing / Intake Manifold Lead
Overview
Work-in-progress custom intake manifold design focused on high-performing runner/plenum geometry and a cheap, manufacturable design
Emphasis on smooth flow transitions, high volumetric efficiency (VE), and optimized velocity stack design
Documenting design revisions and decision-making as the model evolves
My Role
Led the intake manifold concept and owned the CAD model through multiple design iterations
3D-scanned the OEM throttle body and used the scan data to accurately model a flange
Supported prototyping/fitment/testing through 3D-printing and fed results back into design updates
Provided research, guidance, and technical direction for the team, helping understand requirements, avoid common mistakes, and keep the project moving
Challenges
Managing tradeoffs between runner shape/length targets and overall manifold size/complexity
Creating clean internal transitions without sacrificing manufacturability
Keeping airflow to a maximum, even with a restrictor plate
Working within tight clearance constraints near the firewall while maintaining serviceability