Lexus Supercharger R&D Internship
Summer 2020 automotive internship — supercharger prototype CAD, supplier coordination, and drawing-standard automation for forced-induction kits.
Domaine du projet
Conception mécanique
Key Features
Multi-iteration supercharger prototypes
Domestic and overseas supplier loops
Drawing standard refactor utility
Scope of work
Summer R&D internship focused on Lexus forced-induction kits and the gap between SolidWorks assemblies and installable hardware:
- Model supercharger housings, bracketry, pulley layouts, and clearance to OEM crash structure
- Iterate prototypes for belt wrap, charge-air routing, and service access
- Coordinate domestic and international suppliers on castings, billet, and sheet metal
- Refactor legacy drawing title blocks and BOM formats via utility script
- Mentor parallel intern workstreams on drawing consistency
Out of scope: final EPA/CARB certification, mass production tooling sign-off.
Timeline
| Phase | Window | Milestone |
|---|---|---|
| Onboarding | Jun 2020 | Shop standards, kit architecture overview |
| Prototype CAD | Jun–Aug 2020 | Rev A–D assemblies with clearance studies |
| Supplier loops | Jul–Aug 2020 | Sample cast/bracket review and rejection cycles |
| Drawing utility | Aug 2020 | Bulk title-block and BOM normalization |
| Closeout | Sep 2020 | Handoff notes for fall production planning |
Stack & BOM (process)
| Item | Role |
|---|---|
| SolidWorks | 3D assemblies + manufacturing drawings |
| In-house shop | Billet/print fixtures for fit checks |
| Domestic fab vendors | Short-lead brackets and weldments |
| Overseas casting vendors | Scale hardware — longer loop, lower unit cost |
| Drawing refactor script | Enforce consistent release package format |
Deliverables
- Multiple prototype CAD revisions with clearance reports
- Supplier quote packages with explicit tolerances and finishes
- Shop-floor fit validation on machined/printed mockups
- Drawing standard migration for legacy kit documentation
- Production tooling release (post-internship)
Outcomes
- Learned DFM as a conversation, not an export click
- Reduced drawing inconsistency that previously caused rework on bracket orders
- Built supplier literacy: timezone, sample approval, and “break sharp edges” notes matter
Lessons captured
- Hood-line and thermal growth move together — isometric views lie
- Overseas samples need dimensional reports, not verbal “looks close”
Journal de bord & récit
Périmètre, calendrier et nomenclature sont ici. Pour le contexte et les décisions, voir l’article associé.
Lire l’articleCompleted on: 1 sept. 2020