About Afonso
Portuguese
Native or bilingual
English
Fluent
German
Basic
Experience
- HOLON GmbHE&E Thermal System OwnerAUTOMOBILEApril 2025 - Today (1 year and 2 months)Paderborn, GermanySystem Owner for the Thermal Management System (TMS) of an L4 autonomous electric mover, supporting reliable vehicle operation, passenger comfort, and autonomous system operation.Own system architecture, requirements, and interfaces covering HVAC, thermal actuators, sensors, and the Thermal Management Control Unit (TMCU), including software–hardware interfaces.Lead supplier management for thermal systems, enforcing RFQ scope, technical requirements, delivery milestones, and maturity targets.Owned and executed the RFQ for a new thermal system solution, defining technical scope, requirements, and supplier strategy, resulting in a predicted ~€50M fleet-level total cost of ownership (TCO) reduction through 2034.Support design decisions considering customer experience, energy efficiency, operational uptime, and cost, directly influencing system scalability for fleet deployment.
- Vasco Da Gama CoLABProject CoordinatorENERGY AND UTILITIESMarch 2024 - March 2025 (1 year and 1 month)Porto, PortugalLed end-to-end development of an advanced battery module, coordinating a 7-member team across 3 departments. Designed and validated a direct liquid cooling system sustaining 5C discharge, maintaining maximum cell temperature < 35 °C and ΔT < 5 °C.Performed application benchmarking and requirement definition to align technical solutions with target use cases.Developed dedicated test systems to evaluate battery performance and correlate analytical, simulation, and experimental results. Thermal simulation methodologies within <3% average error between simulationand test results.
- TESLAMechanical Design Engineer - Battery InternAUTOMOBILESeptember 2023 - February 2024 (6 months)Berlin, GermanyPrimary Project: Contributed to the design and validation of an innovative cooling system, enabling a 20% reduction in system costs and a 35% decrease in weight.Led the manufacturing campaign for a scaled-down Model Y battery pack for safety design validation.Coordinated with an international team to ensure build quality control. Applied a 5S methodology, which reduced manufacturing cycle time by 50% and improved build quality by 35%.Developed test specifications focused on thermal runaway product validation. Organised test execution and ensured compliance with outsourced test facilities.Developed test systems to evaluate the performance of the design solution, validating theoretical calculations against real system performance. Leveraged cumulative knowledge in battery manufacturing to create a representative test system.
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Education
- Master's in Mechanical EngineeringFaculty of Engineering of the University of Porto2024
- Bachelor'sFaculty of Engineering of the University of Porto2021