SHUTTLE BUS DESIGN
Design and engineered a modular steel body structure onto an OEM cutaway chassis and cab for a para transit bus platform. Performed FEA simulations for rollover, roof crush, and side/rear impacts in compliance with NHTSA, IIHS, FMVSS, and ECE regulations, validated against physical test data. Supported full vehicle instrumentation and executed durability testing per Altoona standards, followed by load case development for CAE correlation.
Key Highlights:
- Achieved 250 lbs. mass reduction on wheel-well floor variant and 350+ lbs. on flat floor variant
- Developed modular spot-welded steel structure adaptable across GM and Ford cutaway chassis
- Unified cage design reduced part count and enabled low-cost country manufacturing strategy
- Optimized fixturing and seam weld layout for increased throughput and over 6 hours of labor savings
- Designed and validated to meet 7-year/200,000-mile Altoona durability and FMVSS 207/210, 214, 220, and
- ECE-R66 compliance
