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I am a mechanical and automation engineer with hands-on experience across manufacturing, mechanical design, and automation in industrial environments. I thrive at the intersection of mechanical systems, data pipelines, and process improvement, drawing on experience from Tesla and Hatch to deliver measurable improvements.…

Matthew Carullo

Designer, Graphic Designer, Product Designer, +2

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I am a mechanical and automation engineer with hands-on experience across manufacturing, mechanical design, and automation in industrial environments. I thrive at the intersection of mechanical systems, data pipelines, and process improvement, drawing on experience from Tesla and Hatch to deliver measurable improvements.…

Available to hire

I am a mechanical and automation engineer with hands-on experience across manufacturing, mechanical design, and automation in industrial environments.

I thrive at the intersection of mechanical systems, data pipelines, and process improvement, drawing on experience from Tesla and Hatch to deliver measurable improvements.

Skills

Experience Level

Expert

Expert

Expert

Expert

Intermediate

Intermediate

Intermediate

Language

English

Fluent

Work Experience

Mechanical & Automation Engineer at Hatch Ltd.

August 1, 2024 - Present

Built an automated Python signal-processing pipeline to replace a fully manual FFT interpretation workflow, implementing dominant frequency detection and classification, error analysis, and automated reporting. This project cut analysis time by 40% and improved defect classification accuracy by 30%.

Mechanical Engineer at Tesla Inc.

May 1, 2023 - August 1, 2023

Engineered mechanical design revisions for high-speed lithium-ion cell manufacturing lines using SolidWorks and GD&T, standardizing improvements across global automation platforms via PLM systems. Diagnosed excessive backlash and vibration in a high-throughput infeed gearbox through dynamic analysis and root-cause investigation, driving a mechanical redesign that improved powertrain precision and reduced cycle-time variability by 20%. Designed a custom in-line inspection tool for mechanical sealing machinery, enabling real-time seal validation and supporting a 25% boost in QA throughput.

Mechanical Engineer at Tesla Inc.

September 1, 2022 - December 1, 2022

Performed FMEA on Semi-truck cabin components, qualifying water ingress risk and informing design changes ahead of launch. Designed a 3D-printable drip guard with full DFM analysis for scalable production, preventing an estimated $600K in electronics damage across early fleet builds.

Manufacturing Engineer at Tesla Inc.

January 1, 2022 - April 1, 2022

Led process improvement studies on laser welding systems in lithium-ion cell assembly, increasing machine yield from 92% to 99.8% through targeted validation and equipment optimization. Prototyped a machine-learning vision system for automated weld classification, applying feature extraction and supervised learning techniques to reduce false negatives. Implemented offline quality control measures across key assembly line stages, improving defect detection and production conformance.