Ford / SK Battery Plant – $5.5B

Projects

Mechanical, Electrical & Plumbing Commissioning

Mechanical Design: Commissioned HVAC and industrial dehumidification systems supporting EV battery manufacturing environments to maintain strict temperature, humidity, and particulate control requirements critical to lithium-ion cell production. Verified system operation through functional performance testing, controls integration validation, airflow balancing coordination, and sequence-of-operations testing to ensure stable environmental conditions across production spaces.

Neon sign displaying the words "BlueValley" and "Electric Vehicle Center" with an outline of a bridge and the word "Tennessee".
Industrial manufacturing facility with extensive stainless steel pipes, machinery, and control panels, featuring a staircase and elevated platform.

Supported functional testing and commissioning activities for equipment including air handlers, desiccant dehumidification systems, chilled water systems, and building automation controls to reduce contamination risk, prevent moisture-related defects, and maintain manufacturing reliability.

An aerial view of a large industrial complex with multiple buildings, pipes, and construction activities, surrounded by a forested area.
An aerial view of a large industrial complex with multiple buildings, pipes, and construction activities, surrounded by a forested area.

EV Charger (EVSE) : J1772 to J3400 (Tesla) PCB Adaptation

Designed a 16A SAE J1772 EVSE compatible with Ford Lightning vehicles, including support for J3400/NACS-equipped vehicles via a J1772-to-J3400 adapter.

Technical diagram of an AC power charging gun for electric vehicles, displaying wiring details, dimensions, cable specifications, and components such as a control box and Euro standard plug.

Performed root-cause analysis on Control Pilot (CP) signaling issues including PWM duty cycle timing and missing –12V low-phase swing. Implemented firmware fixes for real-time PWM duty update and CP voltage validation, and redesigned the CP hardware stage by adding a 1kΩ pull-down resistor, 1N4148 diode, and 0.1µF filter capacitor for clean ±12V CP waveform. Updated PCB layout and verified with DRC (0 errors).

Technical drawing of a Tesla electric vehicle charging station with detailed measurements and components such as supercharger posts, conduits, grounding, and pavement markings.
Technical schematic drawing of electrical one-line diagram for electric vehicle charging stations, including diagrams, notes, and specifications.