Mechanical Engineering · Automotive

Evan Ruga

Mechanical Engineering student at Ohio Northern University with hands-on experience in mechanical systems, CAD design, fabrication, and automotive engineering. Certified SOLIDWORKS Professional (CSWP) with experience as Suspension Design Lead for Baja SAE competition vehicles for Polar Bear Racing, as well as rebuilding internal combustion engines.

SolidWorks 2,500+ hrs
CSWP · CSWA
FEA
TIG · MIG · CNC · Laser
Bambu P1S · PAHT-CF

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Baja car number 32 driving hard through loose dirt, front suspension compressed and dirt spraying from the tires — ONU Baja SAE car #32 (2025–26), testing before Baja SAE Ohio

My October 2026 resume: education, experience, and skills. This site covers the projects in more depth.

Download resume (PDF)

01 / ABOUT

Design-first, hands-on

I'm a mechanical engineering student at Ohio Northern University (Ada, OH), in the automotive concentration, graduating in May 2028. I do my best work at the front end of a project: defining requirements, laying out geometry in CAD, checking it with FEA, and getting a physical prototype in hand quickly.

I've spent more than 2,500 hours in SolidWorks and hold the CSWP and CSWA, both earned in the Engineering Technology program at the Allegan AESA Tech Center (completed May 2024). That program also included FANUC robot teaching and a trip to AUTOMATE 2024. On the shop side I TIG and MIG weld aluminum and steel, run manual and CNC lathes and mills, laser-cut, and print functional parts in engineering plastics.

Looking for: internships in automotive design, FEA, and prototyping, as well as AI hardware roles.

Beyond engineering: captain of the Allegan High School men's tennis team (2020–2024); two-time doubles qualifier at the conference, regional, and state levels, and Coaches Award recipient.

School: Ohio Northern Univ.
Degree: BS ME, Automotive
Graduation: May 2028
Team role: Baja SAE Suspension Lead
SolidWorks: 2,500+ hrs
Certs: CSWP · CSWA

02 / PROJECTS

Selected work

Each project covers the objective, approach, my role, and the key numbers. Dimensions are in imperial units.

Baja SAE Independent Long-Travel Suspension

Ohio Northern University Baja SAE (Polar Bear Racing) · Suspension Design Lead · Fall 2024–present · cars #49 (2024–25) and #32 (2025–26)

Design · FEA · Prototyping

Objective

Redesign the full independent long-travel suspension for an off-road car that weighs ~400 lb without a driver and up to ~600 lb with one. The targets were ride quality and travel over rough terrain, with unsprung mass kept low.

Approach

Set a ride-frequency target of ~0.93 Hz and worked back to spring rates through the front motion ratio (~1.5:1, wheel travel / shock travel).
Specified dual-rate springs on Genesis GX shocks (7.5 in front stroke) to balance small-bump compliance against bottoming resistance.
Designed control arms in 1.000 × 0.065 in 4130 tube with 1/4 in Grade 5 bolts in double shear at the outer joints.
Modeled the suspension as flexible SolidWorks assemblies, part of the team's first comprehensive digital twin of the car.
Ran FEA on arms and joints.
Fabricated the suspension components, including H-arms, A-arms, and tie-rods.

wheel rate = spring rate / MR² (MR ≈ 1.5)
f_ride = (1/2π)·√(k_wheel / m_sprung) → target ≈ 0.93 Hz

My role

Suspension Design Lead, responsible for initial geometry and layout, FEA of suspension members, and prototyping through fabrication. Also pit crew lead: managed time-sensitive major repairs throughout an international endurance race against Division I programs.

Outcome

After the full suspension redesign, the team passed SAE Baja Suspension & Traction, Technical Inspection, and Course Completion for the first time in eight years.

Placed 8th in Suspension & Traction at Baja SAE South Carolina 2025.

Key numbers
Vehicle mass (no driver)	~400 lb
Max mass (with driver)	~600 lb
Architecture	Independent, long-travel
Shocks	Genesis GX
Front shock stroke	7.5 in
Front motion ratio	~1.5:1 (wheel/shock)
Front unsprung mass	~15 lb
Ride frequency target	~0.93 Hz
Springs	Dual-rate
Control arm tube	4130, 1.000 × 0.065 in
Outer joints	1/4 in Gr. 5, double shear

Baja car number 32 cresting a dirt mound head-on with one front wheel drooped and mud flying, under a cloudy sky — Testing before Baja SAE Ohio, car #32 (2025–26)

Baja car number 32 blasting through a muddy water hole in front of a cornfield, spray rising around the car — Testing before Baja SAE Ohio, car #32 (2025–26)

Baja car number 32 turning hard across a muddy field, tires throwing dirt — Testing before Baja SAE Ohio, car #32 (2025–26)

Baja car number 32 climbing a dirt mound with the inside front wheel lifted, trees and cloudy sky behind — Testing before Baja SAE Ohio, car #32 (2025–26)

Side view of Baja car number 32 on a dirt track with its suspension loaded, green fields behind — Testing before Baja SAE Ohio, car #32 (2025–26)

Orange Baja car number 49 in a tight panning shot, background streaked, dirt kicking off the rear — Car #49 (2024–25), panning shot

Baja car number 49 with its front wheel lifting over a log obstacle, showing suspension travel — Car #49 (2024–25) on the log obstacle

In SolidWorks

SolidWorks render of a Baja SAE front corner: knobby tire, upright, teal upper and lower A-arms and an orange coilover mounted to the frame — Front corner assembly: tire, upright, A-arms, coilover

Dimensioned 2D SolidWorks sketch of the full-width front suspension geometry with construction lines to the instant centers and roll center — Front suspension geometry sketch, full width, with instant-center and roll-center construction lines

SolidWorks render of an upright assembled with a bearing and a slotted brake rotor — Upright with bearing and brake rotor

SolidWorks Simulation stress plot of a cylindrical housing with a bore; load arrows inside the bore and fixtures at the base; no legend shown — FEA stress plot: cylindrical housing with a bore, bore load and base fixture shown (view 1)

More CAD & analysis

03 / SKILLS

Skills & certifications

CAD through finished part.

Design & analysis

SolidWorks 3D and 2D: 2,500+ hrs
Weldments and sheet metal
Design for manufacturability
FEA of suspension members

Fabrication & machining

TIG and MIG welding, aluminum and steel
Lathe: CNC and manual
End mill
Laser cutting
Suspension fabrication

Automotive

Suspension systems and shock tuning
Combustion engines: teardown and rebuild
Brakes, drivetrain, and general repair

AI tools

AI for productivity, self-development, and Baja SAE team organization

Prototyping & electronics

3D printing: Bambu Lab P1S
PAHT-CF, PA6, TPU and other engineering plastics
Arduino instrumentation

Coursework

Ohio Northern University, B.S. Mechanical Engineering

Engineering

ENGR 1041 Foundations of Design 1
ENGR 1051 Foundations of Design 2
ENGR 2131 Statics
ENGR 2141 Dynamics
ENGR 2231 Strength of Materials
ENGR 2601 EPICS
ECCS 2311 Electric Circuits

Mechanical engineering

ME 1411 Engineering Material Science
ME 2311 Thermodynamics
ME 2411 Design for Manufacturing
ME 2511 Computer Applications
ME 2521 Experimentation Fundamentals

Math & science

MATH 1631 Calculus 1
MATH 1641 Calculus 2
MATH 2651 Differential Equations
MATH 3061 Discrete Mathematics
PHYS 2311 Physics 1
PHYS 2341 Physics Laboratory 1
CHEM 1501 Chemistry for Engineering
CHEM 1551 Chemistry for Engineering Lab

Business & humanities

ABUS 2221 Principles of Entrepreneurship
ENGL 1221 Writing Seminar
PHIL 2401 Professional Ethics
MUSC 1001 Music Appreciation

In progress

ME 3121 Machine Component Design
ME 3211 Dynamic Systems Modeling
ME 3311 Fluid Mechanics
ME 3511 Sensors & Measurements
PHYS 2321 Physics 2

Transfer credit

ENGR 1000N Engineering (transfer elective)

CSWP

Certified SOLIDWORKS Professional (CSWP)Parametric part and assembly design · May 3, 2024 · all three segments passed at 100% (3/20, 4/22, 5/3/2024)

CSWA

Certified SOLIDWORKS Associate (CSWA)Dassault Systèmes · Oct 31, 2023

FANUC

FANUC Robot TeachingAllegan AESA Tech Center

OSHA 10 · CPR/AED

04 / PROJECTS

More projects

Personal aero work on my Camaro and functional 3D-printed parts.

2019 Camaro SS 1LE: Aero Package & 3D-Printed Duckbill

Personal project

Design · Additive · Fabrication

Objective

Build a front-to-rear aero package for my 2019 Camaro SS 1LE: splitter, side skirts, a ZL1 1LE-style wing, and dive planes. The centerpiece is a custom segmented duckbill spoiler designed and printed in-house.

Approach

Modeled a ~53 in wide, ~7 in tall duckbill in SolidWorks at ~45° initial angle, then revised the angle in a later iteration.
Split the part into segments to fit the Bambu Lab P1S build volume and printed it.
Mounted it with fasteners through the trunk holes, taped the edges, then primed and painted.
Looked at reinforcement options for the ZL1 1LE-style wing.

My role

Sole designer and builder: CAD, segmentation, printing, finishing, and installation.

Duckbill key numbers
Width	~53 in
Height	~7 in
Initial angle	~45° (later revised)
Construction	Segmented FDM print
Printer	Bambu Lab P1S
Mounting	Through trunk holes
Finish	Edges taped, primed, painted

Other aero parts

Front splitter
Side skirts
ZL1 1LE-style rear wing
Dive planes

Black Camaro from ground level at blue hour, two streetlights framing it — Blue-hour shoot, 10/13/2024

Brick sidewalk leading to a black Camaro with a church steeple and sunset behind — Downtown at sunset, 10/13/2024

A black Mustang and a black Camaro parked together on a lit downtown street at night — With a Mustang, winter night shoot 2025

Black Camaro, front three-quarter view, framed by bare trees in a plaza at golden hour — Front 3/4 view with new wing, 6/1/2025

Rear of a black Camaro, taillights lit, centered in front of a garage door at dusk — Rear view at dusk

Backlit rear wing and rear end of a black Camaro with sun flare, vertical frame — New rear wing, backlit

Duckbill CAD

SolidWorks duckbill spoiler surface model positioned on a 3D scan of the Camaro trunk lid — Duckbill model fitted to a 3D scan of the trunk lid

Closer view of the duckbill outline on the 3D scan of the Camaro trunk lid — Duckbill on the trunk-lid scan, closer view

SolidWorks surface model of the duckbill spoiler in an isometric view — Duckbill surface model, iso view

SolidWorks surface model of the duckbill spoiler seen from the rear, showing the end plates — Duckbill, rear view with end plates

Duckbill side-profile sketch (spline), dimensioned

Duckbill side section

Functional 3D-Printed Parts in Engineering Plastics

Personal & team work · Bambu Lab P1S

Design for AM · Rapid prototyping

Objective

Make end-use and prototype parts directly from CAD, using engineering filaments where PLA won't handle the heat, load, or flex.

Approach

Choose material per job: PAHT-CF for stiff, heat-tolerant structural parts; PA6 for tough general-purpose parts; TPU for seals and compliant features.
Design for the process: orient for load paths, segment large parts, and add features for inserts and fasteners.
Iterate fast: print, fit, revise CAD, reprint.

Part types

Aero pieces
Intake housings
Seals and gaskets (TPU)
Fixtures and jigs
Design prototypes / fit-check models

Process
Printer	Bambu Lab P1S
Materials	PAHT-CF, PA6, TPU, others
CAD	SolidWorks

05 / OTHER WORK

Other projects

Restorations, rebuilds, and CAD work outside the main projects.

'95 Ford F150 Restoration

Personal · 2023–2025

Rebuilt a 1995 Ford F150, focused on front suspension, braking systems, and 4x4 drivetrain components. Designed and fabricated a custom transmission crossmember to correct drivetrain geometry from a prior lift modification.

Front suspension, brakes, and 4x4 drivetrain components rebuilt
Body panel painting: paint-code matching, two-part clear coat, professional spray equipment

'97 Ford Ranger 4.0L V6 4x4 Restoration

Personal · 2021

Brought a Ranger back after it had sat unused for several years.

Replaced the starter, spark plugs, freeze plugs, braking system, exhaust, and sensors
Refurbished the interior, repainted exterior sections, and installed a new stereo

Bobcat Skid Steer: Kubota V1702 Diesel Rebuild

Personal · Bobcat skid steer · 2023–2025

Full extraction and teardown of the skid steer's Kubota V1702 4-cylinder diesel after internal rust damage.

Sourced replacement parts and coordinated machine-shop work: cylinder re-bore, crankshaft polish, valve work
Reassembled the engine, verified mechanical tolerances, and reinstalled it

Baja SAE CAD & analysis

SolidWorks work on the Baja SAE car. I'm the suspension design lead. I assembled the full-vehicle model; the frame and drivetrain are my teammates' work, and the steering rack was carried over from a previous car and modified by me. Select an image to view it larger.

Full vehicle

SolidWorks full-vehicle assembly of the Baja SAE car seen from the front, with wheels, A-arms and coilovers — Full-vehicle assembly, front view (assembled by me; suspension designed by me; other subsystems by teammates)

SolidWorks isometric view of the Baja SAE chassis with front and rear suspension, coilovers, hubs and rotors, wheels hidden — Chassis and suspension, iso view without wheels (assembled by me; suspension designed by me; other subsystems by teammates)

Front suspension

SolidWorks side view of a Baja SAE front corner showing the coilover, A-arm, hub and brake rotor — Front corner from the side: coilover, A-arm, hub and rotor

SolidWorks front view of the Baja SAE front suspension with A-arms, coilovers and uprights, and the steering shaft with its U-joint — Front suspension, front view: A-arms, coilovers, uprights, steering shaft

Rear suspension

SolidWorks isometric view of the Baja SAE rear end with wheels: teal and black suspension arms, orange coilovers and hubs, with the frame and engine behind them — Rear suspension, iso view with wheels: arms, coilovers, hubs (frame and engine/drivetrain by teammates)

SolidWorks side view of the Baja SAE rear end: teal suspension arm, orange coilover and wheel, with the engine and frame — Rear suspension, side view: arm, coilover, wheel (frame and engine/drivetrain by teammates)

SolidWorks isometric view from the front side of the Baja SAE rear section with the firewall panel, one rear suspension corner with arms, coilover and wheel — Rear corner, iso view from the front side with the firewall panel: arms, coilover, wheel (frame, firewall and drivetrain by teammates)

Steering

Uprights

SolidWorks render of a machined front upright with bearing bore, A-arm mounting ears and steering arm — Front upright model

Shaded SolidWorks model of an upright with bearing bore and mounting ears — Upright (knuckle) model, shaded view

SolidWorks drawing of the 2024–25 left front upright for Baja SAE, Ohio Northern University, with section views A-A and B-B, material 6061-T6, scale 1:2 — Drawing: 2024–25 left front upright, sections A-A and B-B, 6061-T6

Suspension geometry

2D SolidWorks half-car suspension sketch with the droop position drawn in blue over the ride position — Half-car kinematics sketch with the droop position overlaid in blue

Dimensioned 2D SolidWorks half-car suspension kinematics sketch — Half-car kinematics sketch, dimensioned

SolidWorks global-variables table listing the arm lengths, heights and offsets that drive the suspension sketch — Global variables that drive the parametric suspension sketch

FEA

Second view of the SolidWorks Simulation stress plot of the cylindrical housing with a bore; no legend shown — FEA stress plot: same housing, second view

CAD & drawing samples

SolidWorks A-size drawing of a cylindrical bike rack with nine views, dimensioned 41.50 in diameter top, 20.00 in band height, and 20.5 in diameter base, scale 1:48 — Bike rack: SolidWorks drawing, inches, 1:48

SolidWorks exploded-view drawing of the bike rack showing the top cap, band, rings, and vertical bars, with 20.00 and 44.00 in dimensions — Bike rack: exploded view

SolidWorks model of a triangulated truss bridge structure on four legs — Truss bridge: SolidWorks model

06 / PHOTOGRAPHY

Photography

I shoot cars and motorsport, including my own team's car at competition. Shoots are grouped by category, newest first. Each shows a few highlights; open the full shoot to see every photo. Select a photo to view it larger.