Overview
Joined Bugatti Rimac in the Fall of 2024 to experience High-end Hyper Car Development, taking on the role of Exterior Project Engineer with a focus on Trim and Composite Development.
The move to Bugatti marked a significant step away from conventional OEM development, offering exposure to rapid prototyping, 3D printing, cross-department collaboration and hands-on work in Composite Design, Vehicle Assembly and Part Feasibility studies.
"MACARON" BADGE
A clear highlight of the Bugatti experience was the development of the full Silver and Enamel main badge, also referred to as the "Macaron".
As the responsible engineer for the development, solutions were investigated, to integrate this valuable crown piece into the already impressive vehicle.
Hand crafted from pure Silver and adorned with Enamel, the badge presented an exciting manufacturing and Quality Control challenge, particularly the final assembly concept to the Carbon Front Pillar.
The end product is an impressive piece, presented front and centre as the crown jewel of the Tourbillon.
COMPOSITE DEVELOPMENT
The main responsibility at Bugatti Rimac was the development of various composite parts, primarily located in the Front Zone of the Tourbillon.
This period provided valuable learning in Carbon Part design, Carbon sheet layup strategies, manufacturing feasibility and end-of-line Quality assessments.
A highlight of that development was the design of very prominent parts of the vehicle, including the Front Pillar and Splitter, as well as the concepting of a special blend of Carbon and Fibreglass into a single part. This was later used for a speciality antenna cover.
FINISHERS AND TRIM
Another point of pride was the concepting and design of the various Aluminium Exterior Trims seen on the Tourbillon.
These were a demanding set of parts to work with, due to stringent weight and stiffness requirements.
They required considerable attention and manual reworking on live prototype cars to achieve the right fit, ensure correct Gap & Flush conditions and provide a solid, dependable fixing solution for Series Production.
CLUSTER & WATCHMAKING
Although not a part that fell within the scope of responsibility, the Analogue Central Cluster was one of the most impressive parts seen on the car.
For me personally, as an avid watchmaker, it was a dream come true to see this marvel of fine mechanical engineering in action, and it inspired me to take my favourite hobby to the next level.