Hello, I’m Lewis James Carruthers. I’m a CAD/BIM specialist with extensive experience supporting mechanical services and HVAC systems in GMP-regulated pharmaceutical environments. I’ve led drawing offices, coordinated ducting and piping layouts, and maintained large technical drawing libraries to ensure accuracy and compliance across projects. I excel at interpreting HVAC schematics, updating as-built drawings, and collaborating with engineering and facilities teams to deliver precise documentation and efficient workflows.
I’m now looking to transition into a full HVAC Draftsperson role, bringing deep system knowledge, hands-on problem solving, and a proven track record of delivering accurate drawings and model updates that support real-world operations and capital projects.
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Custom 72V E‑Bike Battery & 3D‑Printed Frame‑Integrated Enclosure
I designed and built a custom high‑voltage e‑bike battery system to overcome the limited internal space of my mountain bike frame. The project combined 3D scanning, CAD modelling, iterative 3D printing, and hands‑on battery assembly to create a precision‑fit 72V pack tailored exactly to the bike’s geometry.
Frame Scan & CAD Modelling
Using an iPhone LiDAR scanning app, I captured an accurate 3D model of the bike frame and imported it into AutoCAD. From this, I created a clean digital reference and mapped out a battery layout that preserved full rear‑shock movement. The optimised design accommodated 60 cylindrical cells, enabling a 20s3p configuration suitable for a 72V system.
Custom Enclosure Design
I designed a multi‑piece enclosure shaped precisely to the scanned frame triangle. Several 3D‑printed prototypes were produced to refine mounting points, structural rigidity, cable routing, and suspension clearance. The final prototype achieved a perfect fit with full range‑of‑motion clearance.
Component Selection & Fitment
I sourced high‑quality P50B 2700mAh lithium‑ion cells and all required assembly materials. Honeycomb cell holders were used to maximise packing efficiency and maintain consistent spacing. A full dry‑fit confirmed the 60‑cell array aligned with the enclosure and frame geometry.
Battery Assembly
The pack was assembled in a 20s3p layout, welded and interconnected with appropriate insulation and structural reinforcement. A 150A Daly BMS was integrated to manage charge, discharge, and cell balancing. The completed pack fit cleanly into the final enclosure with secure mounting and tidy cable routing.
Outcome
The finished system is a custom‑engineered 72V battery pack that:
Fits the frame with millimetre‑level precision
Maintains full suspension travel
Provides increased power and range
Demonstrates end‑to‑end capability across digital design, prototyping, and fabrication
This project highlights my ability to combine digital engineering tools with practical hands‑on execution, delivering a tailored solution to a real‑world design constraint
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