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Axel Brennan
Mechanical Engineer

Built for speed.Engineered for precision.

Axel Brennan, Mechanical Engineer
Race-Proven

I'm a mechanical engineer who designs, simulates, and races what I build — from motorsport components to automated production lines that run twenty-four hours a day.

60+Components shipped
0.2sLap time gained
9Years in motorsport eng.
4Patents filed
SolidWorks Fusion 360 Ansys AutoCAD KISSsoft Moldflow Altair OptiStruct Six Sigma SolidWorks Fusion 360 Ansys AutoCAD KISSsoft Moldflow Altair OptiStruct Six Sigma
01About

From CAD model to checkered flag.

Focus areas

  • Mechanical design & GD&T
  • FEA / CFD simulation
  • Motorsport & powertrain components
  • DFM & production automation

I'm a mechanical engineer who lives at the intersection of CAD models and the shop floor. I design parts in SolidWorks in the morning, validate them with FEA by lunch, and watch them spin on a test rig by the end of the day.

A part that only survives in simulation hasn't been engineered yet. I design for the worst tolerance stack, the worst material batch, and the worst day the part will ever see.

Indianapolis, INOpen to senior design roles
02Design Process

Four gates. Every part.

01

Concept

Sketch geometry, define load cases, and lock the functional requirements.

02

CAD Model

Parametric solid modeling with full GD&T and tolerance stack-up.

03

Simulate

FEA and CFD validation against real-world load and thermal cases.

04

Validate

Physical prototyping, test-rig data, and sign-off for production.

03Engineering Work

Parts that earned their place.

Tilt a card — every part here passed simulation before it ever touched a track or a line.

NO. 01Motorsport · CFD

GT4 Brake Cooling Duct

Designed a 3D-printed brake cooling duct that cut rotor temps by 60°C across a full race stint.

SolidWorksAnsys FluentMarkforged
  • Rotor temps down 60°C
  • 0.2s/lap gain in late-race stints
  • Adopted across the full GT4 grid
NO. 02Automation · Production

Robotic Weld Cell Redesign

Redesigned a 6-axis robotic weld cell fixture to cut cycle time on a high-volume chassis line.

SolidWorksAutoCADSix Sigma
  • 22% faster cycle time
  • Zero fixture-related defects in 6 months
  • Retooled in a single weekend
NO. 03Motorsport · Topology Optimization

Lightweight Suspension Upright

Topology-optimized a forged aluminum suspension upright, cutting unsprung mass without losing stiffness.

Fusion 360AnsysAltair OptiStruct
  • 31% mass reduction
  • Stiffness within 2% of baseline
  • Passed full fatigue testing
NO. 04Industrial · Power Transmission

Conveyor Drive Gearbox

Specified and packaged a custom gearbox for a high-throughput conveyor line running three shifts a day.

SolidWorksKISSsoftGD&T
  • Zero unplanned downtime in year one
  • 18-month ROI on energy savings
  • Rated for continuous duty
NO. 05Motorsport · Mechanism Design

Quick-Release Pit Wheel Hub

Designed a quick-release wheel hub mechanism to shave seconds off pit-stop tire changes.

SolidWorksFusion 360Rapid Prototyping
  • 1.1s faster average pit stop
  • Zero hub failures across a full season
  • Adopted by two race teams
NO. 06Product Design · Consumer

HVAC Damper Actuator

Designed an injection-molded damper actuator mechanism for a residential smart-HVAC product line.

SolidWorksMoldflowDFM Review
  • 40% part-count reduction
  • Passed 100k-cycle durability test
  • Shipped in 200k+ units
04Exploded View

Every assembly, taken apart.

Keep scrolling — the stack stays pinned while it separates, the same view I check before any part goes to the shop floor.

REV CTOP COVER
REV AGASKET SEAL
REV DMAIN HOUSING
REV BBASE MOUNT
EXPLODE0%
05In The Shop

Where the model meets the metal.

06Experience

Nine years on the line.

Senior Mechanical Engineer · Apex Performance Engineering

2020 — Present

Lead mechanical design for motorsport components, from concept through race-day validation.

Motorsport DesignFEA/CFDTeam Leadership

Mechanical Engineer · Ironclad Automation

2017 — 2020

Designed fixtures and automated tooling for high-volume automotive production lines.

Production AutomationDFMGD&T

Design Engineer, Co-op · Ironclad Automation

2015 — 2017

Rotated through design, simulation, and the shop floor while finishing a mechanical engineering degree.

SolidWorksPrototypingSix Sigma
07Skills

Redlined and verified.

Design & Analysis

95%SolidWorks / Fusion 360
88%FEA (Ansys)
80%CFD (Fluent)
92%GD&T / Tolerance Stack-Up

Production & Tools

90%DFM / DFA
78%Six Sigma (Green Belt)
85%Rapid Prototyping
75%PLM / PDM
08Credentials

Papers to back the parts.

B.S. in Mechanical Engineering

Purdue University

2015

Certified SolidWorks Professional (CSWP)

Dassault Systèmes

2017

Six Sigma Green Belt

ASQ

2019

FE Exam — Mechanical

NCEES

2016

09From The Paddock

What the team says.

Axel shaved two-tenths off our lap time with a part that weighed less and survived twice as long. That's the whole job, done right.
Maria SolisTeam Principal, Apex GT Racing
He's the engineer you call when the line is down and you need a fix that's still standing in six months.
Devon CaldwellPlant Manager, Ironclad Automation
Axel's tolerance stack-ups have saved us from at least three expensive tooling mistakes.
Priya NairManufacturing Engineer, Ironclad Automation
10Get In Touch

Got a part to design?

Race components, production tooling, or a mechanism that needs to survive the real world — send the brief.

© 2026 Axel BrennanIndianapolis, IN