EUNSUNG KIM / MECHANICAL ENGINEER

Mechanical design.
Systems integration.

I develop mechanical hardware across requirements, design, validation, and production support. My experience connects automotive steering systems and consumer electronics, with a focus on physical interfaces, engineering trade-offs, and test evidence.

Microsoft · Mechanical Engineer II · Dec 2025–present
Honda R&D · Steering Systems Design Engineer → Senior · Oct 2021–Nov 2025
GearLab / The Ohio State University · Gear durability and fatigue research · Aug 2019–May 2021

Download resume

SYSTEMS INTEGRATION / MICROSOFT

Resolve integration questions early.

Translate laptop experience goals into system and subsystem requirements. Compare concept CAD, physical interfaces, feasibility, and integration strategies with partner teams. Earlier 2-in-1 work balanced potential SoC power headroom against package space through CAD and simulation iterations.

Requirements · Packaging · Thermal-mechanical trade-offs

PRODUCT DEVELOPMENT / HONDA

Carry requirements through validation and release.

Developed belt-drive EPS gearbox components through mechanical design, DV/PV, drawing release, and production support. Balanced cost, weight, performance, and manufacturability with suppliers; coordinated part maturation and delay-recovery plans around build and test milestones.

EPS gearboxes · DFM/DFA · Supplier coordination

DURABILITY / GEARLAB

Connect measured damage to failure analysis.

At the Gear and Power Transmission Research Laboratory, The Ohio State University, combined controlled spur-gear durability tests, precision surface measurements, and fatigue analysis to investigate how wear influences pitting locations.

Test development · MATLAB · Precision inspection

ONE EXAMPLE / GEARLAB RESEARCH

Measure the change. Revisit the model.

Problem: Gear-tooth surfaces change during durability testing. I investigated how that deterioration relates to where pitting develops.
What I drove: I developed an all-tooth damage-tracking procedure and compared fatigue calculations using initial geometry with calculations updated from measured worn surfaces.
What changed: With worn geometry included, predicted damage concentrations were near the observed pitting regions in the two-pair study. The analysis connected measured deterioration to potential failure locations.

See methods, evidence & study limits ↗

HARDWARE DEVELOPMENT / CROSS-INDUSTRY EXPERIENCE

Make the design work as part of a system.

I evaluate mechanical interfaces alongside performance, manufacturability, assembly access, and reliability. My experience spans early concept studies at Microsoft and component development through production at Honda, supported by hands-on durability research.

Common steering-gearbox development also gave me experience contributing to hardware intended for use across future vehicle models.

M.S. & B.S. in Mechanical Engineering · The Ohio State University

Explore the work

A SPATIAL PUZZLE

Every piece has a place.

Rotate, flip, and fit four pieces into one board. Fill every square and try to beat the record.

MY WORK / RELIABILITY & TESTING

Design. Test.
Understand.

Durability research, automotive validation and failure investigation, and a bearing failure detection GUI—connecting test evidence, failure mechanisms, and engineering decisions.

Durability testingDV / PV coordinationRoot-cause analysisFMEA / FTAMATLABPrecision inspection

01 / GEARLAB · MASTER’S RESEARCH · 2021

From surface damage to fatigue failure

Gear and Power Transmission Research Laboratory · The Ohio State University
M.S. Mechanical Engineering · Advisor: Dr. David Talbot

Problem: Understand how evolving gear-tooth surface damage relates to contact-fatigue failure.
What I drove: Developed an all-tooth damage-tracking procedure, with inspections every 2–3 million cycles, to follow deterioration and identify the teeth that failed.
Analysis approach: Used measured worn geometry alongside initial geometry in contact-stress and fatigue calculations, then compared predicted damage concentrations with observed pitting.
Result: Incorporating worn geometry placed predicted damage concentrations near observed pitting regions in the two-pair study. This linked measured surface changes to potential failure locations, not a validated time-to-failure prediction.

Test methods, measurements & analysis details

Durability tests & inspection

Studied two spur-gear pairs at different torque levels using a GL100 back-to-back test rig, with controlled speed, lubricant conditions, and temperature.
Developed an all-tooth damage-tracking procedure, rather than following one selected tooth; inspected at intervals of 2–3 million cycles to track deterioration and identify the teeth that failed.
Used a Klingelnberg P26 CMM for tooth topography, a Talysurf profilometer for surface roughness, and macroscopic photographs to relate measured geometry changes to visible damage.

Measurement-to-model analysis

Processed CMM topography in MATLAB for WindowsLDP contact-stress calculations; quantified surface degradation through profile deviation and roughness parameters Ra, Rq, and Rz.
Applied the established Fatemi–Socie critical-plane fatigue criterion and Palmgren–Miner damage accumulation rule to evaluate subsurface fatigue damage.
Compared calculations using initial geometry with calculations updated from measured, worn surfaces, then compared damage concentrations with observed pitting locations.

Key finding

Wear and micropitting altered tooth geometry and shifted contact-stress concentrations. Updating the analysis with measured surface changes placed predicted damage concentrations near the observed pitting regions—showing why the condition of a component matters, not only its original geometry.

Evidence boundary: A two-pair study linking measured deterioration to potential failure locations—not a validated time-to-failure model. Crack-initiation timing and depth were not established experimentally.

Relevance to reliability engineering: Controlled testing, repeatable metrology, failure-mechanism analysis, and comparison of model predictions with physical evidence.

02 / HONDA R&D AMERICAS · OCT 2021–NOV 2025

Steering-system validation & failure investigation

Steering Systems Design Engineer → Senior Steering Systems Design Engineer

My belt-drive electric power steering (EPS) gearbox work included component validation, vehicle-test investigations, and field-failure analysis. I worked with reliability, CAE, testing, and supplier teams to connect test findings to mechanical design corrections.

Validation & test coordination

Coordinated design validation (DV) and product validation (PV) testing with reliability and testing partners.
Aligned supplier part maturation, build and shipping readiness, test deadlines, and technical-evaluation timing.
Evaluated component-validation and vehicle-test findings against engineering requirements, drawing on strength, durability, and performance calculations developed with partner teams.

Failure analysis & design response

Investigated failed validation results, vehicle-test issues, and field failures through root-cause analysis.
Used failure mode and effects analysis (FMEA) to assess potential failure modes and their effects, and fault tree analysis (FTA) to structure possible contributing causes.
Worked with suppliers and internal partners to implement long-term design corrections and communicate findings through engineering documentation and technical updates.

Engineering focus

Understanding what a failed test reveals, separating possible causes from supporting evidence, and translating the investigation into an implementable design response.

03 / ETEGENT TECHNOLOGIES · MAY–JUL 2019

Bearing failure detection GUI

Mechanical Engineering Intern

Developed a graphical user interface (GUI) for a bearing failure detection tool, connecting vibration analysis with the evaluation of ball-bearing dynamic behavior.

Interface development

Created the GUI for the bearing failure detection tool.
Brought the analysis into an interactive interface for evaluating bearing behavior.

Vibration & component behavior

Built a custom vibration-analysis tool for ball-bearing components.
Used vibration analysis to evaluate dynamic behavior in the context of bearing failure detection.

Engineering focus

Connecting mechanical behavior, vibration analysis, and a usable engineering interface to support bearing-failure investigation.

CONNECTED EXPERIENCE

Use physical evidence to guide the design response.

Controlled gear tests, precision inspection, and fatigue analysis taught me to compare modeled behavior with measured damage. At Honda, I connected component and vehicle-test findings to requirements and worked with design, supplier, and test partners on corrections. Together, these experiences shape how I approach mechanical design, validation, and hardware reliability.

MINI GAME / SPATIAL THINKING

Perfect Fit_

TIME00:00.0

Four pieces. 16 squares. Rotate and flip to fill the entire board.

★ 4 × 4 RECORD—Loading record…

Ready to make it fit?

Fill every square. No gaps. No overlaps.

0 / 16 FILLED4 × 4 BOARD

Your timer starts when you press Start. Take a look at the pieces first.

How to play & records

Click or tap a piece, then a board square. Each piece’s dotted anchor square lands where you click. R rotates clockwise; F mirrors horizontally. Use arrow keys on the board and Enter to place. Undo does not stop the timer.

The timer continues while you switch tabs. Restart begins a new attempt. A completed board is checked and timed on the server; verification includes network travel time. The fastest saved time stays until someone beats it. Ties keep the existing record.

This is a spatial puzzle inspired by fitting parts within an envelope—not a simulation of engineering clearances or a company product.

AUTOMOTIVE / HONDA R&D · OCT 2021–NOV 2025

From requirements
to production support.

Belt-drive EPS gearbox development, chassis interfaces, validation, and drawing release—with supplier management and schedule recovery throughout development.

From the driver’s seat.

01 / AUTOMOTIVE

Selected vehicles from my steering-system work at Honda R&D.

01Honda PilotSTEERING SYSTEMS

02Honda PassportSTEERING SYSTEMS

03Acura MDXSTEERING SYSTEMS

Steering components / a quick referenceMy Honda work ↓

▣ Steering system — Component explorerVIEW 01 / 04

FRONT ← SYSTEM

Steering system

Column → gearbox and rack → tie rods → front wheels.

MY WORK / HONDA R&D AMERICAS

My work at Honda.

I worked across the product lifecycle, from trim-level feature requirements and chassis definition through component development, validation, engineering release, and production support. My primary component focus was the steering gearbox, including belt-drive electric power steering (EPS) systems.

01 / REQUIREMENTS & CHASSIS DEFINITION

Translate vehicle features into requirements

Worked from feature lists for different vehicle trims and new functions to define steering-component needs.
Collaborated with suspension, brake-system, reliability, computer-aided engineering (CAE), and testing teams on chassis structure and kinematic hard points.
Coordinated strength, durability, and performance calculations with partner teams to inform component specifications.

02 / STEERING GEARBOX DEVELOPMENT

Develop the EPS component and its interfaces

Developed belt-drive electric power steering gearboxes, coordinating component requirements with the surrounding chassis system.
Created and updated CATIA V5/V6 models, drawings, and specifications, applying GD&T and design-for-manufacture and assembly principles.
Worked with suppliers on design refinements and cost, weight, performance, and manufacturability trade-offs.

03 / SUPPLIER MANAGEMENT & SCHEDULE RECOVERY

Drive progress with a supplier-specific strategy

Managed supplier communication and follow-up to drive part maturation, build readiness, and shipping commitments.
Built schedules and intermediate milestones around each supplier’s capabilities, working patterns, and areas requiring closer follow-up.
Adapted communication cadence and follow-up priorities based on experience with each supplier, balancing constructive collaboration with accountability for commitments.
Worked through build and delivery delays with suppliers and internal teams to develop recovery plans and revise near-term priorities.
Aligned supplier milestones with component availability, validation-test deadlines, and technical-evaluation timing.

04 / DESIGN & PRODUCT VALIDATION

Connect component evidence to vehicle behavior

Coordinated design validation (DV) and product validation (PV) testing with reliability and test partners.
Evaluated component-validation and vehicle-test findings against engineering requirements.
Worked across design, analysis, and testing teams to investigate failed results and determine the design response.

05 / FAILURE & RISK ANALYSIS

Understand failure modes and contributing causes

Used failure mode and effects analysis (FMEA) to assess potential failure modes and their effects, and fault tree analysis (FTA) to structure possible causes.
Investigated component-validation failures, vehicle-test issues, and field failures through root-cause analysis.
Connected findings to long-term design corrections with supplier, reliability, and testing partners.

06 / RELEASE & PRODUCTION SUPPORT

Carry the design through release

Prepared and issued component drawings and specifications as designs matured.
Coordinated with quality, manufacturing, and supply-chain teams on integration and production considerations.
Maintained engineering documentation and technical updates through development milestones and production support.

STEERING SYSTEMS DESIGN ENGINEER · OCT 2021–DEC 2024
SENIOR STEERING SYSTEMS DESIGN ENGINEER · DEC 2024–NOV 2025

PLATFORM DEVELOPMENT / HONDA R&D

A common steering gearbox.
Future vehicle models.

Alongside vehicle-specific steering work, I contributed to the development of a common steering gearbox for future vehicle models during my time at Honda.

SHARED STEERING PLATFORM DEVELOPMENT

CONSUMER HARDWARE / MICROSOFT

Requirements.
Interfaces. Integration.

My work has progressed from thermal-mechanical studies for a 2-in-1 device to early laptop-platform development—connecting product experiences, technical feasibility, and mechanical integration.

SELECTED CONTRIBUTIONS / MICROSOFT · DEC 2025–PRESENT

Explore early. Make the trade-offs clear.

01 / CURRENT FOCUS · LAPTOP PLATFORMS

Prepare technology for product integration

Objective: Explore technology and integration questions early so product-development teams have a clearer technical foundation before execution schedules become compressed.

Work with partner teams to understand intended laptop experiences and translate them into system- and subsystem-level questions.
Define and explore requirements, interfaces, and mechanical concepts before detailed product development.
Evaluate technical feasibility, potential benefits, trade-offs, and integration constraints with specialists.
Develop concept options and integration strategies that product-development teams can carry forward, making assumptions and unresolved questions explicit.

Work products: Technical concepts, feasibility studies, benefit and trade-off assessments, and integration considerations for downstream development.

02 / CASE STUDY · 2-IN-1 THERMAL DEVELOPMENT

Balance power headroom and packaging space

Problem: Explore additional system-on-chip (SoC) power headroom while limiting the space required by the thermal solution.
What I drove: Iterated mechanical CAD with thermal specialists, using simulation findings to guide successive geometry updates for a compact 2-in-1 device.
Decision criteria: Compared thermal-performance potential against packaging and integration constraints, rather than judging a concept by thermal performance alone.
Work product: Updated CAD concepts and comparisons of thermal and mechanical trade-offs to support the next design iteration. This was simulation-informed development, not a claim of shipped performance.

These summaries describe my contribution at a general level, not sole ownership or a product-release claim. Internal program details and work samples are not included.

FORM FACTOR / 01

The 2-in-1

A Surface-inspired character for a product that sits between tablet and laptop.

FORM FACTOR / 02

The laptop

A familiar form, with a tightly connected world of components inside.

These Surface-inspired illustrations represent form factors, not specific products or generations. Internal architectures, performance values, technology roadmaps, and work samples are not shown.

MECHANICAL ENGINEER II · MICROSOFT · DEC 2025–PRESENT

Eunsung Kim

Mechanical Design and Systems Integration

Redmond, WA · U.S. Citizen

eunsungk.18@gmail.com LinkedIn

Summary

Mechanical engineer with an M.S. and experience developing automotive steering components through production and integrating consumer hardware. Combines requirements definition, CAD, GD&T, and thermal-mechanical trade studies with durability testing and failure analysis. Coordinates suppliers and cross-functional teams to resolve design constraints, mature hardware, and support validation and delivery milestones.

Experience

Microsoft

Dec 2025 - Present

Mechanical Engineer II

Partnered with the thermal team on 2-in-1 device development, iterating mechanical CAD and simulations to evaluate additional system-on-chip (SoC) power headroom within constrained package space.
Develop mechanical concepts for next-generation laptop platforms. Translate partner-team feature goals into system and subsystem requirements, assessing technology feasibility, benefits, trade-offs, and integration strategy before product development.
Create concept CAD to evaluate component envelopes, mounting, structural support, clearances, and assembly access. Compare packaging alternatives and document integration constraints for multidisciplinary design discussions.
Support prototype and enclosure integration with mechanical, electrical, industrial-design, and manufacturing partners, coordinating material and assembly requirements and evaluating manufacturability and serviceability.

Honda R&D Americas, LLC

Oct 2021 - Nov 2025

Senior Steering Systems Design Engineer | Dec 2024 - Nov 2025
Steering Systems Design Engineer | Oct 2021 - Dec 2024

Developed belt-drive electric power steering (EPS) gearbox components for Honda Pilot, Passport, and Acura MDX from requirements through validation, drawing release, and production support. Contributed to common steering gearbox development for future vehicle platforms.
Created and released CATIA V5/V6 models, drawings, and component specifications using GD&T, tolerance stack analysis, and DFM/DFA. Refined designs with suppliers to balance manufacturability, cost, weight, and performance.
Worked with suspension, brake, CAE, reliability, and test teams to define chassis interfaces and kinematic points, translating vehicle feature requirements and strength, durability, and performance inputs into part specifications.
Coordinated design validation (DV) and product validation (PV) with component and vehicle testing. Used root-cause analysis, FMEA, and fault tree analysis to investigate failures and work with suppliers and internal teams on design corrections.
Managed supplier part maturation, build and shipping deadlines, and technical evaluation timing. Built milestones around supplier capabilities and working patterns, escalating delays and developing recovery plans to support validation schedules.

Gear and Power Transmission Research Laboratory

Aug 2019 - May 2021

GearLab at The Ohio State University
Graduate and Undergraduate Research Assistant

Developed and executed spur-gear durability test protocols to investigate micropitting and contact fatigue. Tested two gear pairs at different torque levels on a GL100 back-to-back rig with controlled speed, lubrication, and temperature.
Developed an all-tooth damage-tracking procedure with inspections every 2-3 million cycles. Used Klingelnberg P26 CMM measurements, Talysurf profilometry, and photographs to track geometry, roughness, and surface damage.
Processed measured tooth topography in MATLAB for WindowsLDP contact-stress calculations. Applied Fatemi-Socie fatigue analysis and Palmgren-Miner damage accumulation to compare predicted damage with observed pitting.
Compared calculations using initial and worn geometry with test evidence. Including measured surface changes placed predicted damage concentrations near observed failure regions in the two-pair study.

Master's thesis: An Investigation of the Influence of Micropitting on the Progression of Gear Surface Pitting (2021).

Etegent Technologies

May 2019 - Jul 2019

Mechanical Engineering Intern

Developed a graphical user interface for a bearing failure detection tool, using vibration analysis to evaluate ball-bearing dynamic behavior and support failure investigation.

Technical Skills

CAD and mechanical definition: PTC Creo, CATIA V5/V6, SolidWorks; component and assembly design; engineering drawings and specifications; GD&T; tolerance stack and dimensional data analysis.

Hardware integration: Requirements definition, mechanical interfaces, EPS gearbox development, consumer-electronics packaging, mounting and clearances, prototype integration, thermal-mechanical collaboration, feasibility and trade studies.

Manufacturing and execution: DFM/DFA, assembly access and serviceability, supplier coordination and part maturation, build planning, schedule recovery, engineering release, production support, common-platform development.

Validation and analysis: DV/PV coordination, durability test protocols, root-cause analysis, FMEA, FTA, MATLAB, WindowsLDP, contact-stress and fatigue analysis, vibration analysis, CMM measurement and surface profilometry.

Education

The Ohio State University
M.S. Mechanical Engineering, May 2021
B.S. Mechanical Engineering, May 2020

C:\EUNSUNG\ABOUT.TXT

Curious about
how things fit.

I’m Eunsung Kim, a Mechanical Engineer II at Microsoft focused on early laptop-platform development and mechanical integration.

My recent work connects thermal-mechanical design, technology feasibility, and cross-functional product development. Previously, I developed automotive steering systems from requirements through validation and production support. Durability research and failure analysis underpin how I evaluate design decisions.

Experience, most recent first

DEC 2025
— PRESENT
Microsoft
Mechanical Engineer II
- Early laptop-platform studies: product experiences, system and subsystem requirements, technology feasibility, trade-offs, and integration strategy.
- Earlier 2-in-1 work: thermal-team collaboration, iterative CAD and simulation studies, and the balance between SoC power headroom and packaging space.
OCT 2021
— NOV 2025
Honda R&D Americas
Senior Steering Systems Design Engineer · Dec 2024–Nov 2025
Steering Systems Design Engineer · Oct 2021–Dec 2024
- Belt-drive EPS steering-gearbox development across requirements, chassis integration, validation, drawing release, and production support.
- Supplier management: tailored communication, schedules, and milestones to each supplier’s strengths and constraints; drove build readiness and developed delay-recovery plans.
- Component and vehicle-test failure investigations, FMEA and FTA, and common steering-platform development.
AUG 2019
— MAY 2021
Gear and Power Transmission Research Laboratory (GearLab)
The Ohio State University
Graduate and Undergraduate Research Assistant
- Gear durability research combining controlled tests, precision surface measurements, MATLAB analysis, and fatigue-damage modeling.
MAY 2019
— JUL 2019
Etegent Technologies
Mechanical Engineering Intern
- GUI development for a bearing failure detection tool using vibration analysis.

The tools behind the work

PTC CreoCATIA V5/V6SolidWorksGD&TTolerance analysisDFM / DFAMATLABRoot-cause analysisPrototype integration

EDUCATION / THE OHIO STATE UNIVERSITY

M.S. Mechanical Engineering · May 2021
B.S. Mechanical Engineering · May 2020

Outside of work

Tennis
Shared rallies, steady practice, and quick adjustments.
Camping
Thoughtful preparation and resourceful solutions when plans change.
Skiing
Focus, adaptability, and confidence built through practice.
Board games
Thinking ahead, exploring trade-offs, and connecting through play.

C:\EUNSUNG\CONTACT

Let’s talk
engineering.

Interested in mechanical product design, hardware integration, or reliability engineering? I’d welcome a conversation.

eunsungk.18@gmail.comOPEN EMAIL ↗ Eunsung Kim on LinkedInVIEW PROFILE ↗

Mechanical design.Systems integration.

Resolve integration questions early.

Carry requirements through validation and release.

Connect measured damage to failure analysis.

Measure the change. Revisit the model.

Make the design work as part of a system.

Explore the work

Every piece has a place.

Durability tests & inspection

Measurement-to-model analysis

Validation & test coordination

Failure analysis & design response

Interface development

Vibration & component behavior

Use physical evidence to guide the design response.

Perfect fit!

From requirementsto production support.

From the driver’s seat.

Steering system

My work at Honda.

Translate vehicle features into requirements

Develop the EPS component and its interfaces

Drive progress with a supplier-specific strategy

Connect component evidence to vehicle behavior

Understand failure modes and contributing causes

Carry the design through release

A common steering gearbox.Future vehicle models.

Requirements.Interfaces. Integration.

Explore early. Make the trade-offs clear.

Prepare technology for product integration

Balance power headroom and packaging space

The 2-in-1

The laptop

Summary

Experience

Microsoft

Honda R&D Americas, LLC

Gear and Power Transmission Research Laboratory

Etegent Technologies

Technical Skills

Education

Curious abouthow things fit.

Experience, most recent first

Microsoft

Honda R&D Americas

Gear and Power Transmission Research Laboratory (GearLab)

Etegent Technologies

The tools behind the work

Outside of work

Tennis

Camping

Skiing

Board games

Let’s talkengineering.

Eunsung’s desktop

Mechanical design.
Systems integration.

From requirements
to production support.

A common steering gearbox.
Future vehicle models.

Requirements.
Interfaces. Integration.

Curious about
how things fit.

Let’s talk
engineering.