Justin
Padgett

Engineer by education.
Mechanic by trade.
Maker by the work I actually do.

Discipline
Mechanical / Design & Fabrication
Based
Phoenix, Arizona
Contact
Justinpadgett6@gmail.com
Profile
linkedin.com/in/justinrpadgett

Built Work

03 projects

Lehigh Racing · Formula SAE · Senior Capstone · 2025–2026

LR-26 Aerodynamics Package

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Fabrication & Manufacturing Lead

The first complete aerodynamic package in the team's history, developed by a four-engineer capstone group. I owned the tooling and mounting hardware that turned an aerodynamic concept into a part that could survive a race weekend — CNC foam split molds, prepreg layup, and the rear-wing mounting structure. When the course ended, the car still needed layups, hardware, and finishing, so I kept working until it was ready to compete.

  • CFD
  • Mold CNC
  • Prepreg Layup
  • Oven Cure
  • Mounting
  • Competition
The completed car with the rear wing mounted
Built car, rear wing
Test mold used to trial the split-mold clamshell prepreg layup method
Layup method trial, split mold
Assembled rear wing with endplates
Rear wing assembled
Materials
Prepreg carbon fiber, machined aluminum, tooling foam
Tools
ANSYS Fluent, SolidWorks, CNC mill, autoclave oven
Outcome
Passed tech inspection and ran the full FSAE Michigan event with measured lap-time gains

NB Center for American Heritage · Precision Motor Cars · Summer 2025

Machining & Historic Work

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Designer / Apprentice Machinist

Restoration work on engines and vehicles where a scrapped part has no replacement and the original drawings are long gone. I rebuilt and machined historic engines end to end, reverse-engineered tolerances from surviving hardware, and designed the parts and test fixtures the shop needed but could no longer buy — bringing modern CAD, CNC, and additive methods to machinery built decades before any of them existed.

  • Teardown
  • Diagnostics
  • Reverse Engineering
  • Machining
  • Installation
Pressure test plates for a straight-eight engine block
Pressure plates, I8
All-aluminum V16 engine block with the crankshaft exposed
Aluminum V16, mid-rebuild
Restored automobiles in the collection hall
The collection
Materials
Aluminum, cast iron, steel
Tools
CNC and manual mill, lathe, precision measurement
Constraint
Irreplaceable components — no second attempt on a bad cut

Wilbur's Design Labs, Lehigh University · 2024–2026

Project Specialist

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Parts Designer & Fabrication Lead · Project Specialist

In-house designer and fabricator for academic departments, research groups, and student organizations across campus. Most customers knew what they needed but not how to specify it, so the job started with translation: turn a description into requirements, requirements into drawings, and drawings into a finished object that arrives on time. I selected the process to match the job — CNC milling, plasma, laser, lathe, welding, or hand tools — and scheduled concurrent work so competing deadlines all held.

Wilbur's is Lehigh's maker space, a wood and metal shop open to every student on campus. The AAD department used it most, so most of my work went to them: machined aluminum components, cut steel, furniture, and commissioned pieces.

  • Requirements
  • CAD
  • Drawings
  • Process Selection
  • Delivery
Aluminum part being machined on a CNC mill under coolant
Machining a client part
Live-edge river table with blue epoxy inlay
Live-edge river table
Customers
Faculty, research groups, student organizations, AAD department
Tools
SolidWorks, Fusion 360, CNC mill, plasma, laser, lathe, welding
Constraint
Non-engineer customers, fixed deadlines, shared shop capacity

ATLAS Vehicle Performance

2022 – present

A self-directed design and fabrication practice I started to keep building outside coursework. Custom parts modeled in SolidWorks, checked in FEA, then machined or fabricated to the requirements of each build.

The completed Challenger off-road build, lifted and on all-terrain tires

Challenger Off-Road Conversion

A platform with no aftermarket support and no factory reference geometry, so every bracket is an original design problem. Front bumper with integrated radiator relocation, suspension lift spacers, hard-mounted roof rack, light bar mounts, strut brace, and exhaust — validated by annual cross-country driving.

Steel & aluminum · CAD → FEA → weld → field test

Full minibike CAD assembly with the calculated center of mass marked

Tubular Minibike Chassis

A CAD design study built around a Honda GX390: a large engine in a small frame, with the chassis cut down far enough to leave real suspension travel. Center of gravity was balanced in-model from material properties rather than guessed at. The harder constraint was my own shop — with no precision bender, the design leans on notched joints and repeatable bend references.

SolidWorks weldments · 3D sketch · CG from material properties · design for a shop without a bender

Welded steel pendulum impact rig built to deliver repeatable strikes to composite test panels

Denim Composite Study

Custom body panels in carbon are expensive. I ran a study on 100% cotton denim as a cheap, renewable alternative, testing it directly against carbon on a pendulum rig I built: 1,060 g hammer on a 16-inch arm from 90°, roughly 4.22 J per strike, ten strikes per panel. Denim held its shape well but went brittle from resin absorption and fractured by the tenth strike. Worth another round of testing with the epoxy controlled.

Pendulum impact rig · denim vs. carbon vs. fiberglass · 4.22 J per strike

Roll cage welded into a BMW track car

Client Fabrication

Structural tube work built to customer requirements — tubular doors for a Jeep Wrangler and a roll cage for a BMW track car. Both are safety-adjacent parts fitted to a chassis I did not design, so each job starts by measuring the customer's actual vehicle rather than working from a drawing.

Requirements → drawings → fabrication → install

Lehigh University Car Club

2022 – 2026

Joined as a mechanic and design consultant, then served as Treasurer, Vice President, and President. Revived a defunct organization into one of the largest on campus, directing a 17-person board across operations, fabrication, events, and finances.

Presenting to club members at a meeting

Leadership

I joined as a general member. My first position was Treasurer, then design consultant, then merchandise lead alongside Vice President. By my last years I was holding Vice President, fabricator, mechanic, and merchandise simultaneously — and then President on top of all of it.

The roles stacked rather than handed off, which is what running a club that had to rebuild itself actually looks like. Whoever could do a job kept doing it while taking on the next one.

As President I directed a 17-person board across operations, finances, fabrication, events, charity work, and outreach — and spent as much time developing the people who would replace me as running the thing itself.

General member → Treasurer → Design Consultant → Merchandise Lead → Vice President → President

Club merchandise laid out, the last shirt design before graduating

Self-Funding Program

The university cut the annual allocation to $500 — less than one event cost. The spending wasn't the problem; the funding model was. I founded a merchandise operation to replace it, developed the product line, and restored an unused campus screen printer so production stayed in-house while capital exposure was highest. It generated $4,000–$5,000 per semester and covered debt service on two club vehicles.

Root cause → make vs. buy → production → debt service

The club garage where members work on cars

Endurance Racing League

Launched in partnership with the Rossin College of Engineering. I assigned proposal and budget development to my secretary, treasurer, and vice president, secured departmental approval and funding, then handed execution to the board that replaced me and stayed on as an advisor.

Proposal · budget · approval · succession

A member learning manual transmission in the club Miata

Miata Teaching Platform

Acquired a 1998 Miata and swapped an NB engine into the NA chassis to build a shared platform for teaching manual driving and basic maintenance to members who had never worked on a car.

Engine swap · instruction platform

Working underneath a club member's car

Club Fabrication

Design and fabrication lead on member and club vehicles: exhaust systems, bumpers, strut braces, seat brackets, and one-off replacements for parts that no longer exist. Also sole instructor for the club's fabrication lessons.

One-off parts · welding · instruction

Members and their cars gathered on campus

Building the Community

The club was never really about cars. Cars were the excuse. The point was giving people somewhere to belong, and a reason to show up and work on something together.

That meant charity events, maintenance clinics for students who could not afford a shop, teaching members to drive manual, fabrication lessons, go-kart outings, and outreach and networking events. Some members arrived having never opened a hood, and left able to do their own work.

It went from defunct to one of the largest organizations on campus, which is the outcome I am proudest of. Everything else on this page — the funding operation, the racing league, the shop projects — existed to make that possible.

Charity events · maintenance clinics · driving instruction · outreach

Lehigh Racing · Formula SAE

2021 – 2026

Five years on the team across aerodynamics, ergonomics, design, and driving. The LR-26 aerodynamics package is above under Built Work; the work below is everything else I owned.

Assembled rear wing with endplates on the bench

Aerodynamics

My senior capstone project: the first complete aero package in Lehigh Racing's history, built by a four-engineer group where I was fabrication and manufacturing lead. It ran at Formula SAE Michigan and passed tech inspection.

Covered in full under Built Work — LR-26 Aerodynamics Package

The completed Formula SAE car at competition in the black, gold and silver livery

Visual Identity & Livery

Designed the team's full visual identity — a black, gold, and silver livery drawing on the 1974 Lotus 72, a redesigned team logo, and a custom apparel line. The palette on this site comes from that scheme.

Livery · logo · apparel · Photoshop

Team race hoodie in the black and gold identity, sponsor marks on the sleeves

Merchandise Design

Designed the team's apparel line alongside the livery and logo, so the identity carried off the car and onto the people around it. Same black, gold, and silver scheme, adapted to garments rather than bodywork.

A team that looks like a team recruits better and gets remembered at competition, and the merchandise was the cheapest part of that to get right.

Apparel design · brand identity · Photoshop

Carbon body panel painted, wet sanded and clear coated to a mirror finish

Surface Finishing & Body Panels

Painted and finished the competition car, color-matching to the powder-coated gold chassis. Carried carbon panels through epoxy seal, progressive sanding, clear coat, and polishing to a mirror finish, and applied aircraft fabric body panels as a lighter replacement.

Paint · progressive sand · clear · aircraft fabric

Driving the car at competition

Driving & Vehicle Dynamics

One of the team's drivers, and the member with the most prior vehicle dynamics experience — the only one in the four-person aero group with any. Translated test data into predicted vehicle response and worked out how aero changes would affect handling.

Our team captain also had strong dynamics knowledge and made good calls on balance without prior driving experience; final say on balance targets was theirs.

Test data → predicted response → balance targets

Analysis & Simulation

06 studies

Finite Element Analysis

Auxetic Material Characterization

Modeled auxetic lattice geometries under load, then built and tested physical specimens to measure how far the simulation drifted from real material behavior.

Method
FEA + physical correlation
Tools
ANSYS Workbench

Structural Dynamics

Seismic Response & Damping

Dynamic response of a reinforced concrete structure under seismic loading, with a comparison of damping configurations to reduce peak response.

Method
Transient dynamic FEA
Tools
ANSYS Workbench

Heat Transfer

Rack-Mounted GPU Heat Exchanger

Finned heat exchanger for high-density electronics cooling, with fin geometry and spacing sized against thermal load, airflow, and the volume available in the rack.

Method
Thermal sizing and analysis
Constraint
Fixed packaging volume

Aerospace

Aircraft Design

Conceptual design covering vehicle sizing, aerodynamic performance, and configuration trade studies against mission requirements.

Method
Conceptual sizing, trade study
Scope
Full configuration

Engines & Efficiency

Dyno Data Analysis

Vehicle efficiency and power characterization from engine dynamometer data, including a comparison of inline-four and V8 configurations.

Method
Test data reduction
Source
Engine dyno

Machine Design · Advanced Dynamics

Long-Travel Control Arm

Long-travel control arms sized from hand-calculated motion dynamics. The upper cleared its factor of safety comfortably even in small tubing, so FEA in SolidWorks focused on the lower arm, where the loading drove a plate-steel section over tube. Designed, not yet fabricated.

Method
Hand calculation + FEA
Result
Material and section selection

Skills


Design

SolidWorks, Fusion 360, detailed drawings, reverse engineering, tooling and fixture design

Analysis

ANSYS Workbench (FEA), ANSYS Fluent (CFD), ABAQUS, MATLAB, Python, physical test correlation

Manufacturing

CNC and manual machining, waterjet, laser and plasma cutting, press brake, tube bending, MIG/TIG welding

Composites

Wet and prepreg carbon fiber layup, vacuum bagging, oven cure, CNC mold fabrication, surface finishing

Automotive

Engine rebuild and machining, suspension and drivetrain systems, chassis fabrication, root cause diagnosis

Program

Cost and schedule management, supplier sourcing, budget development, delegation and succession planning