Lexus Supercharger R&D Internship
Summer 2020 automotive internship โ supercharger prototype CAD, supplier coordination, and drawing-standard automation for forced-induction kits.
Project focus
Mechanical design
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 | JunโAug 2020 | Rev AโD assemblies with clearance studies |
| Supplier loops | JulโAug 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 โ 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 โbreak sharp edgesโ notes matter
Lessons captured
- Hood-line and thermal growth move together โ isometric views lie
- Overseas samples need dimensional reports, not verbal โlooks closeโ
Build log & narrative
Scope, timeline, and BOM live here. For decisions, debugging stories, and longer context, read the related blog post.
Read the blog postCompleted on: Sep 1, 2020