Mechanical Engineering & Program Management

I’m Ethan, a mechanical engineering student interested in building and improving real systems, whether that means manufacturing processes, hardware for energy applications, or data-driven tools that make teams more effective. I’ve built everything from battery test hardware and lake cleanup prototypes to vehicle telemetry platforms and VBA automation that streamlines engineering workflows.

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Ethan Salazar headshot

Selected Projects

A few of the systems and prototypes I’ve built.

Vehicle Telemetry System

Multi-sensor DAQ platform for a kart and vehicle: IMU, GNSS, and temperature probes feeding a Python logging pipeline for vehicle dynamics analysis and event classification.

Arduino IMU & GNSS Python

Air Boat for Lake Cleanup

Concept-to-prototype system that removes floating plastics from lakes using structured design methods, stakeholder input, and physical testing of an air-boat collector and comb subsystem.

Systems Design DFM/DFA Prototyping

Low-Cost Battery Test Chamber

Custom high-temperature chamber for Li-ion packs, integrating heating, insulation, and instrumentation for controlled terminal temperature validation and root-cause analysis.

Thermal Test Engineering Documentation

More Projects

Remote Control Kei Truck

Designed and built a custom RC car including chassis, steering, and drivetrain, with documentation covering concept, CAD, testing, and performance evaluation.

CAD Build & Test

Wind Turbine with AC-to-DC Power Conversion

Breadboarded a rectifier, comparator logic, and transistor driver to monitor windmill generator voltage and indicate speed ranges with multi-level LEDs.

Circuits Mechatronics

Fidget Spinner CAD & Manufacturing

Parametric CAD design and analysis of a fidget spinner, including drawing creation, tolerance considerations, and manufacturability.

CAD Drawings

Corporate Manufacturing Documentation

Created a full set of manufacturing tools and documentation including SOP templates, process flowcharts, pack assembly guides, and quality checkpoints.

Manufacturing Documentation Process Design

Experience

Technical Program Manager Intern – Battery Manufacturing

Tesla · Austin, TX · Jan 2025 – Aug 2025

  • Supported development of a pilot battery manufacturing line, coordinating schedules, cross-functional alignment, and readiness milestones
  • Served as the point of contact for a major equipment delivery, coordinating with facilities, construction, and vendor engineering teams
  • Managed material readiness for 10 production lines across multiple countries and programs
  • Built a lightweight Excel VBA automation tool that dramatically reduced processing time and standardized reporting workflows

Operations Intern – Battery Manufacturing

PHD Energy · Austin, TX · May 2024 – Aug 2024

  • Improved U.S. pack assembly processes, cutting build time and increasing consistency for small-batch production
  • Managed suppliers and inventory, reducing delays and supporting delivery of 40+ battery packs
  • Documented critical workflows and resolved layout bottlenecks to support a 2× increase in monthly production capacity

Technical Program Manager Intern – HV Battery Pack Design

Tesla · Palo Alto, CA · Jan 2024 – May 2024

  • Coordinated cross-functional efforts between 8+ teams to deliver 75+ Robotaxi pack test articles on schedule
  • Led build map reviews to align design, test, and assembly teams on instrumentation and validation requirements
  • Implemented inventory tracking for 100+ unique test components, preventing sourcing delays

Test Engineer Intern – Battery Systems

PHD Energy · Austin, TX · Oct 2023 – Dec 2023

  • Commissioned and calibrated lab equipment for Li-ion pack testing, reducing external testing costs and improving turnaround
  • Executed thermal and performance testing for multiple customer pilot programs
  • Designed a custom high-temperature battery test chamber, replacing the need for a commercial unit and enabling internal validation

Research Assistant – Solid-State Battery Reliability

Cockrell School of Engineering, UT Austin · Jan 2023 – Dec 2023

  • Conducted reliability and performance research on all-solid-state battery materials through structured testing and analysis
  • Supported data collection, test fixture development, and lab documentation for ongoing publications and graduate projects

Other Roles

High school & early college · Various locations

  • Shift manager at Chick-fil-A
  • Cleanup crew at In-N-Out
  • Lifeguard at my neighborhood pool
  • Marching band instructor for high school students

Skills & Tools

A refined snapshot of the tools and disciplines I use across mechanical design, manufacturing engineering, technical program management, and embedded systems work.

Mechanical & Manufacturing Engineering

  • SolidWorks CAD
  • DFM/DFA & GD&T fundamentals
  • Prototyping: 3D printing, laser-cutting
  • Assembly planning & MFG documentation
  • Battery pack design fundamentals
  • Process dev & equipment readiness
  • Root-cause analysis & test planning

Data, Tools & Automation

  • Excel & VBA automation
  • Python & MATLAB for analysis
  • Data logging pipelines
  • Gantt, Kanban, Think-Cell
  • Jira, Confluence, ERP/FES systems
  • AI/LLM-assisted workflows

Program Management & Operations

  • Cross-functional collaboration
  • Supplier sourcing & vendor coordination
  • Material readiness & risk mitigation
  • Project planning & execution
  • Stakeholder research & requirements definition
  • Training & process standardization

Embedded Systems & Testing

  • Arduino / ESP32 firmware
  • IMUs, GNSS, temperature probes
  • Calibration workflows & offsets
  • DAQ system design
  • Circuit basics: rectifiers, comparators, drivers
  • Battery & thermal testing

Outside of Engineering

These are a few of the things that shape how I show up as a teammate and engineer.

Longhorn Band & Music

Music has been a core part of my life for as long as I can remember. I started piano at 6 years old and grew into a multi-instrumentalist on horn, trumpet, percussion, and keyboard. Over the past 16 years I have performed in concert bands, jazz groups, marching band, and indoor percussion with audiences ranging from a single person to more than 100,000.

I have spent 9 years in marching band, 12 years in band programs overall, and 5 seasons with the University of Texas Longhorn Band, performing across the country and learning how to execute under pressure with a large team. I am also a composer, arranger, and teacher and I hope to one day run my own piano studio. Music is my passion and continues to shape how I collaborate, lead, and create.

Performing with Longhorn Band Piano and sheet music Marching performance in stadium

People & Mentorship

I really like building communities, whether that means mentoring younger students, helping friends with career decisions, or being the person who organizes things when a group needs direction.

Some of my favorite moments in school have come from supporting other people’s wins. Teaching marching band, helping new students get oriented, volunteering, and sharing what I have learned from internships and projects all reinforce how much I enjoy seeing people grow.

Group event or rehearsal Workshop or team setting

Running, Travel, & Technology

I like staying active through distance running and lifting, and I’m usually planning my next trip somewhere new. I love exploring other countries, learning how people live, and seeing the world from different perspectives. I’m also drawn to cutting-edge technology, especially in cars and energy systems, and I enjoy keeping up with how these industries evolve.

Travel or city view Car or road trip scene

Get in Touch

I’m open to opportunities in manufacturing, embedded systems, vehicle dynamics, and technical program management.

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