Brendan Zotto
Carson,USA
Summary
Innovative electrical engineer with a track record of delivering complex hardware systems from concept to production in fast-paced, multidisciplinary environments. Skilled at bridging advanced technical design with practical implementation to enable transformative technologies. Experienced in collaborating across mechanical, software, and systems engineering teams to solve novel challenges and accelerate product development. Passionate about applying engineering creativity to drive the clean energy transition, and build next-generation solutions for a sustainable future.
Overview
6
6
years of professional experience
Work History
Senior Power Electronics Engineer
Rivian Automotive
Carson, California
10.2021 - Current
- Developed a sophisticated Python-based SVPWM model using motor flux mapping to predict high-voltage bus resonance harmonics, enabling proactive supplier collaboration and eliminating downstream component failures that previously cost significant warranty expenses.
- Designed innovative planar magnetic bias power supplies for gate drivers, achieving superior EMI performance while reducing piece cost by $3-6 per vehicle, saving millions in lifetime production costs, and enabling scalability to 900V systems.
- Resolved a critical 12V backup supply regulation issue under emergency conditions by identifying and mitigating near-field radiated emissions through strategic PCB layout optimization and copper shielding implementation.
- Discovered and corrected on-die temperature measurement inaccuracies, revealing true operating temperatures that are much higher than previously measured, and enabling 15-20°C efficiency improvements through optimized switching parameters via Double Pulse Testing.
- Architecting next-generation 900V/500kW traction inverter systems, incorporating SPI-based gate driver ICs with real-time fault monitoring and adaptive gate drive strength control, reduces the standard 5-year automotive development cycle to 2.5 years.
- Developed a Simulink model using ambient temperature and vehicle drive conditions to accurately predict DC link capacitor stress and lifetime.
- Supported time-sensitive design and manufacturing issues on the production line in Normal, Illinois.
- Built an automated test setup to investigate motor bearing damage due to large common-mode voltage on the motor shaft.
Avionics Engineer II
Blue Origin
Kent, Washington
03.2021 - 07.2021
- Led electrical circuit design of high-reliability, fault-tolerant controller for an upper-stage rocket engine
- Managing design of isolated and non-isolated DC/DC converters and EMI filters with over 90% efficiency and that meet MIL-STD-461 requirements
- Designed fault-tolerant high-power solenoid controller using wide-bandgap semiconductors and isolated gate drivers providing significant thermal, size, and reliability improvements
- Simulated and built novel current-source architecture with variable inductive load compensation to produce stable dynamic operation of hydraulic actuators
- Tested and debugged flight-hardware signal and power integrity issues using high-speed oscilloscopes and simulation software tools
- Completed rigorous worst-case circuit analysis and de-rating to validate design efficacy and meet requirements
- Implemented novel high-voltage ignition system circuit for on-going Human Landing System engine design
Avionics Engineer I
Blue Origin
Kent, Washington
07.2019 - 03.2021
Education
Bachelor of Engineering - Electrical Engineering
Stony Brook University
Stony Brook, New York05.2019
Skills
- Python modeling
- DC/DC power supply design
- Resonant LLC ZVS-based switching converters
- Planar magnetics
- EMI performance optimization
- LTspice, Qspice, MATLAB, SIMPLIS
- ASIL-D fault tolerance design
- Worst Case Circuit Analysis
- Oscilloscope, Spectrum Analyzer, Bode100
- FOC/SVPWM motor control
Senior Capstone Project
Complete electrification of internal combustion engine motorcycle, Formulated high-power direct torque PMDC motor controller system capable of handling up to 120V and 200A, Designed modular passive dissipation BMS system to properly charge and balance up to 28 lithium-ion cells, Awarded first place for senior capstone project from the College of Mechanical Engineering
Accomplishments
- ID-2154-US01 -TEMPERATURE ESTIMATION WITH REDUCED COMPUTATIONAL BURDEN
Timeline
Senior Power Electronics Engineer
Rivian Automotive
10.2021 - Current
Avionics Engineer II
Blue Origin
03.2021 - 07.2021
Avionics Engineer I
Blue Origin
07.2019 - 03.2021
Bachelor of Engineering - Electrical Engineering
Stony Brook University
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