Ford Everest Tremor:
Full-System Integration & Production Validation
The Design-to-Production Lifecycle:
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Phase 1
Conceptual Architecture: Interpreting Ford simulation data to define the protective envelope, including camera zone, front parking sensor and radar activation area. Also, improving the approach angle while increasing the rigidity of the skid plate structure.
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Phase 2
DFM & Material Science: Optimising design of injection-moulded, roto-moulding, vacuum forming and fabrication across all of parts for mass production.
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Phase 3
Prototype & Physical Validation: On-site fitting tests and iterative issue-solving based on PG durability results.
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Phase 4
Tooling & Quality Control: Managing off-tooling sample checking and tooling modifications to ensure "Production-Ready Documentation".
Initial engineering sample installation
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Systems Thinking:
The program was approached as a complete protection system rather than an isolated bullbar design. Alongside the front protection architecture, I was also involved in the design and development of under-vehicle armour, underwing covers, and supporting bracketry systems to ensure a cohesive visual language and functional integration across the entire package. This holistic approach helped create a unified product outcome that balanced protection performance, manufacturability, and vehicle integration.
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Material Expertise:
Worked across multiple injection moulded components, including grilles and fender covers (wing infills), supporting the process from initial concept development through to production release. The development focused on balancing surface quality, tooling feasibility, assembly requirements, and durability while maintaining strong alignment with the overall vehicle design language. Close collaboration with engineering and suppliers ensured the final components achieved both production efficiency and visual refinement.
