Sam Bahrami

University of Toronto Formula Racing (UTFR)

• Owned the chassis structural architecture and load-path design for a Formula SAE electric car, defining tube layout, node geometry, triangulation strategy, and joint design to meet rules and safety requirements.
• Translated suspension/drivetrain and impact load cases into frame requirements using Ansys FEA, MATLAB, and hand calculations, iterating tube sizing and wall thickness to minimize mass while maintaining stiffness.
• Reduced chassis mass by 20% and cost by 43% through simulation-driven optimization and design-for-manufacturing changes (tube selection, joint simplification, and build-time reduction) while preserving structural performance.
• Designed the full manufacturing system: weld fixtures, cut lists, build sequence, and composite panel interfaces to ensure dimensional accuracy, repeatability, and robust load transfer.
• Fabricated and assembled the complete chassis, including TIG welding, composite bonding, and structural integration into the full vehicle platform.

• Provided technical expertise and mentorship across multiple vehicle subsystems and manufacturing processes.
• Supported design reviews, validation testing, and integration planning for the 2025 and 2026 competition vehicles.
• Developed best practices documentation and training materials for incoming team members.

• Managed shop operations, safety protocols, and equipment maintenance for the UTFR fabrication facility.
• Coordinated manufacturing schedules and resource allocation across vehicle subsystems.
• Trained team members on machining, welding, and composite fabrication techniques.

Magna Electronics

• Supported daily production and led improvement projects across multiple radar module assembly lines serving tier-one automotive customers.
• Developed and implemented automation tools, including PLC-driven dispatch systems, to reduce downtime and operator workload, saving 290 minutes per month across production lines.
• Retrofitted and validated production equipment with minimal capital investment, enabling 19 new product variants and increasing PCBA routing capacity within a 7-day implementation window for under $800.
• Coordinated with cross-functional teams and external vendors to deliver cost-effective manufacturing solutions under tight timelines and strict production uptime constraints.
• Completed over 20 continuous improvement initiatives, focusing on traceability, reliability, and operator efficiency through systematic process engineering and fixture design.

Inteplast Bags and Films Corporation

• Implemented a quality management system for plastic bag and film production, developing comprehensive Standard Operating Procedures (SOPs) that significantly improved the efficiency of the preventative maintenance team.
• Gained extensive hands-on experience operating and troubleshooting industrial machinery, resulting in a 10% reduction in manufacturing downtime.
• Collaborated closely with Quality Assurance and Regulatory Affairs to ensure compliance with governmental regulations and international standards, enabling international export and expanding market reach.