Gerasimos Triantafyllou
Mechanical Engineer
Athens
Summary
Mechanical Design Engineer with practical leadership experience at Prom Racing NTUAthens. Focused on design and manufacturing optimization utilizing CAD, CAM, FEA, and GD&T. Accustomed to meeting strict deadlines and delivering reliable results in demanding project environments. Dedicated to improving production workflows, with current specialized study in rotordynamics and tribology.
Overview
3
3
years of professional experience
2
2
Languages
Work History
Chief Technology Office & Head of Mech Design
Prom Racing NTUAthens
Athens, Attica
09.2024 - 09.2025
- 34th Place in the World, 1st Greek team for Formula Student Electric
- 2nd Place Overall in Formula Student Portugal, 1st Place Cost and Manufacturing Event Formula Student Switzerland, 3/3 Endurance Races completed.
- Lead Racecar's Conceptual Design Process.
- Directed a multidisciplinary engineering division of 30 young engineers (Mechanical, Vehicle Dynamics, Aerodynamics), executing high-risk technical decisions that aligned cross-functional goals and improved overall vehicle performance.
- Streamlined the engineering and production schedules, successfully reaching a full vehicle design freeze a month ahead of the previous year's deadline.
- Spearheaded the end-to-end design lifecycle—from conceptualization to detailed mechanical design—of the team's first custom 35kW Permanent Magnet Synchronous Motor (PMSM).
- Engineered the seamless mechanical integration of the autonomous (driverless) pneumatic-hydraulic system, executing critical structural upgrades to the Steering and Pedalbox assemblies to optimize packaging and reduce actuation latency by 7%.
- Managed vehicle CAD assemblies establishing strict modeling protocols to ensure seamless team collaboration and reduce integration conflicts
- Oversaw the complete design and manufacturing lifecycle for all mechanical sub-teams, and authored engineering documentation (Structural Equivalency of the Chassis) to ensure 100% structural and technical compliance with strict competition regulations.
- Successfully defended full-vehicle engineering decisions (Suspension, Chassis, Powertrain, Ergonomics) to industry judges, and pioneered an automated CO2 emission tracking tool for manufacturing processes, securing 4th in the Cost Event World Rankings.
- Directed the end-to-end development—from conceptual design to final production—of a new transmission and drivetrain architecture. Successfully integrated custom CFRP rims and an upgraded motor cooling network, yielding a 25% increase in system stiffness and a 2kg/wheel reduction in unsprung mass.
- Executed track testing utilizing infrared and strain gauges sensors, successfully validating aerodynamic brake duct designs and correlating theoretical suspension loads with real-world racing data.
- 3-Point Bending, Shear and Tensile Tests on CFRP and Kevlar laminated structures and SLM AlSi10Mg specimen for the production of critical drivetrain component and validation.
- Pioneered the development of topology-optimized, AM-produced uprights, leveraging advanced generative design techniques to increase stiffness/weight ration by 20%.
Suspension and Drivetrain Engineer
Prom Racing NTUAthens
10.2022 - 09.2024
- Led the design and comprehensive in-house manufacturing of the first electric Hub-Motor Wheel Assembly.
- Conducted Finite Element Analysis (FEA)—including fatigue, thermal-structural transient, and stiffness evaluation, co-developed a Hybrid Conformal Cooling Jacket with Renishaw, carried-out bearing selection, dynamic life cycle analysis, and pretension mechanism design.
- Spearheaded the integration of advanced Additive Manufacturing processes (SLS, SLM)
- Managed the precision machining (4-Axis CNC Milling, CNC Lathe) of 80% of vehicle components across high-performance materials (Titanium, CFRP, Tool/Stainless Steel) for 2 racing seasons, and oversaw the production and post-processing of Selective Laser Melting (SLM) parts.
- Optimized manufacturing workflows through the implementation of Trochoidal and AI-assisted CAM methodologies and strategic production scheduling, reducing overall production time by one month.
- Instituted comprehensive quality assurance protocols utilizing Coordinate Measuring Machines (CMM) and 3D scanning, and advanced team proficiency in Geometric Dimensioning and Tolerancing (GD&T), ensuring 100% compliance with strict tolerances across all critical assemblies.
- Directed technical procurement and external vendor communications, successfully securing €60,000 in project funding and resources between 2 seasons.
- Executed topology optimization on the suspension rocker arm, integrating machining constraints to yield a 20% mass reduction while maintaining structural integrity.
- Directed the technical onboarding of new personnel through structured training in FEA and CAD, CAM methodologies, and negotiated a strategic partnership to secure accredited CNC machining and safety certifications.
Education
Master of Science - Mechanical Engineering
National Technical University of Athens
Athens 04.2001 -
Skills
SolidWorks, Fusion360
Matlab, Python
Ansys Mechanical, Fluent
NTop
Altair HyperWorks
Zeiss Quality Suite
SolidCam
Optimization Methods (EAs)
SolidCam
Optimization Methods (EAs)
Timeline
Chief Technology Office & Head of Mech Design
Prom Racing NTUAthens
09.2024 - 09.2025
Suspension and Drivetrain Engineer
Prom Racing NTUAthens
10.2022 - 09.2024
Master of Science - Mechanical Engineering
National Technical University of Athens
04.2001 -