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Jesus Hernandez
About
I am a Mechanical Engineering student with 5+ years of CAD experience and expertise in hardware design, failure analysis, and product development. I have successfully led design initiatives across robotics, autonomous vehicles, and assistive devices, combining strong technical skills in CAD, FEA, and product design with a focus on manufacturability and user safety. My work has driven significant cost savings and reliability improvements through innovative problem-solving and cross-functional collaboration.
Media
Experience
Hardware Engineer - Co-Op
Amazon Robotics · Internship
Jul 2025 – Dec 2025 · Westborough, MA
• Developed a dynamic fastener assembly using DFMEA insights, sized solutions according to part tolerances and static/dynamic loads, and led full-scale supplier rollout with installation procedures driving failure rate to 0% • Metrized conveyor-tote kinematics through hand calculations to predict and ensure low pinch forces, increasing tote reliability • Redesigned conveyor system geometry using human-factors principles, improving ergonomics by 3% and reducing transition noise from 70 dB to 50 dB • Redesigned sheet metal and injection molded components with part-to-part conflicts while maintaining GD&T specifications and DFA/DFM standards
Body and Closure Design Engineer - Intern
Zoox · Internship
May 2024 – Aug 2024 · Foster City, CA
• Implemented highly sensitive pinch detection system using strain gauges and pneumatic sensors into vehicle's French door design without affecting A-surface, electrical systems, or core operational software, reducing pinch risk; design is patent pending • Created torque characterization bot for door actuator mapping door path and current draw to develop standardized degradation tests • Conceptualized, manufactured, and troubleshot electromagnetic cycling device to replace unreliable latch-validation rigs using CATIA V6 and Arduino • Conducted pitch-and-yaw door cycling experiment using Python to statistically determine failure rates at extreme angles
Failure Analysis Engineer - Intern
Tesla · Internship
Jan 2024 – May 2024 · Sunnyvale, CA
• Analyzed material structures and electrical components using optical microscopy, profilometers, spectrometers, X-ray, CT scanning, SEM, FTIR, and lock-in thermography to identify design deficiencies and support DFMEA evaluations • Authored internal technical report identifying MOSFET semiconductor failure modes, outlining physical and electrical traits respective to operation region, increasing failure discernment rates by 80% and improving reliability of $20M/yr warranty liability • Invented modular service tool for ball joint replacement focused on material strength, cast mold GD&T principles, and user experience, cutting Tesla's warranty costs by $10M/yr
Assistant Researcher
Rehabilitation Engineering and Assistive Device Lab (REAL) · Part-time
Mar 2021 – Dec 2023 · Orlando, FL
• Applied least squares optimization to reduce high-order polynomial muscle force models into equivalent spring constants, achieving 95% similarity • Designed bi-articulate leg mechanism in SolidWorks using torque sensor as knee joint to replicate leg forces while applying DFM and DFA principles