Sam Bahrami

University of Toronto Formula SAE Racing (UTFR)

• Leading the chassis design, validation, and manufacturing for the UT26 electric Formula SAE vehicle, including full structural layout, subsystem packaging, and rule compliance for the 2026 competition season.
• Managing a subteam of engineers focused on CAD design, FEA validation, and manufacturability, while coordinating integration with the powertrain, suspension, aerodynamics, and accumulator teams.
• Performing FEA using Ansys Mechanical and SolidWorks Simulation to evaluate torsional stiffness, impact loading, and critical mounting points — achieving a 15% increase in rigidity while reducing mass over the previous chassis.
• Developing manufacturing documentation and fixtures such as laser-cut tube jigs and welding assemblies to ensure repeatable and high-precision fabrication.
• Implementing composite and removable plate architectures for improved serviceability and packaging within strict FSAE dimensional and safety constraints.
• Previously designed drivetrain and steering components that achieved a 35% mass reduction in rotating assemblies through topology optimization.
• Contributed to vehicle assembly, validation, and race-prep for Formula SAE Michigan, New Hampshire, and Formula Student Czech Republic, supporting major gains in performance and reliability.

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Drivetrain System

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42 Tooth Sprocket

Magna Electronics

• Supported daily production and led improvement projects across multiple radar module assembly lines.
• Developed and implemented automation tools, including dispatch systems, to reduce downtime and operator workload.
• Retrofitted and validated production equipment, enabling new product variants and increasing PCBA routing capacity.
• Coordinated with cross-functional teams and vendors to deliver cost-effective solutions under tight timelines.
• Completed over 20 continuous improvement initiatives, focusing on traceability, reliability, and operator efficiency.
• Gained extensive experience in PLC programming, equipment validation, and integration of mechanical and software systems.

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Production Line Retrofit

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In-House Programming Development

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.