Mechanical Engineering · Texas LonghornsUT Austin · B.S. 2029

Benjamin Thomas

I work on hardware that has to hold up in the field: race car uprights, rover ground-support carts, competition robot manipulators. I run the analysis, then I go make the part1 1 Aside × Four years of FRC got me in the habit of checking the model against the part on the bench before believing either one2 2 × Yes, a footnote inside a footnote. I thought it was funny. . .

Benjamin Thomas
01 — About

Mechanical engineering at UT Austin, class of 2029, from Houston. I came in through four years of FIRST Robotics on Team 118, where I did manipulator design and ran the CNC router and lathe3 3 Team 118 × World Division Champion, two Texas District Championships, seventeen regional and district wins. 30+ components machined by me across those seasons. . Now I run FEA on the rear upright assembly for Longhorn Racing's combustion car.

Last summer I was an ER4 intern at NASA Johnson Space Center, refurbishing transmission components on the Space Exploration Vehicle and developing CAM for a universal wheel hub4 4 JSC, summer 2025 × Also repaired MicroChariot wheels and prototyped the SEV rain-cover and flagpole. . The summer after, I designed a NASA GSE-style rover troubleshooting cart at the A&M Robotics Automation and Design Lab.

Outside the shop I research how engineers work with AI-generated CAD, a human-subject study I helped design through the FIRE program, and sit on a 12-person team running UT's $2M student venture fund, looking mostly at hardware startups.

02 — Projects
Machined 7075-T6 rear upright rear upright — 7075-T6,
as machined

01 · Longhorn Racing FSAE · 2025–present

Completed

Rear Upright

SolidWorks Ansys FEA nTOP DFM / DFA

Performed finite element analysis on the rear upright assembly of the combustion vehicle to identify the stress concentrations driving component mass, then revised the geometry accordingly. The revision reduced mass by 5% while maintaining a 1.75 safety factor5 5 1.75 × Team minimum; any value below it must be justified in a design review. . Also responsible for the brake line routing and mounting hardware design.

Mass reduction5% vs. prior assembly
Min. safety factor1.75, held
My roleVehicle dynamics engineer

Read the write-up →

02 · A&M Robotics Automation & Design Lab · 2026

Completed

REV GSE Cart

SolidWorks Sheet metal Raspberry Pi FDM / SLA

A rover troubleshooting workstation modeled on NASA ground-support equipment, with a riveted 5052-H32 aluminum frame, gravel-rated casters, a sunlight-readable telemetry display, and Raspberry Pi status indicators. I performed the structural analysis of rivet loading and gusset design and managed procurement for a build of more than 100 items6 6 100+ items × Sourced across several suppliers; lead times influenced the design as much as the analysis did. .

FrameRiveted 5052-H32 aluminum
Also builtAI tool-scanning → foam inserts
My roleDesign, analysis, sourcing

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REV GSE cart with all drawers extended cart with drawers extended
CAD render of the 118 manipulator arm and end effector CAD — manipulator arm
and end effector

03 · FRC Team 118 · 2022–2025

Completed

118 Manipulator

Fusion 360 CNC router Lathe SolidWorks

Four seasons on the manipulator subsystem, responsible for design, manufacturing, and assembly with a team of eight or more students on a six-week build schedule. I machined more than 30 components on the CNC router and lathe and served on the student leadership committee.

ResultsWorld Division Champion
Also2× TX District, 17× regional
My roleSubsystem design, machining

Read the write-up →

04 · Personal build

In progress

World Record Chair

SolidWorks Fusion 360 CNC router

An attempt at the Guinness World Records mark for the thinnest folding chair. The current record is 1.68 cm; the prototype targets under 1.27 cm when stowed while supporting a full adult seated load. Filed with Teddy Garza, with the attempt scheduled at the University of Texas at Austin.

RecordThinnest folding chair
Current mark1.68 cm
StatusApplication logged · pending evidence

Read the write-up →

ink illustration — the chair,
faceted, with figure for scale
ink illustration — front upright,
generative lattice study

05 · Longhorn Racing FSAE · 2026–present

In progress

Front Upright

SolidWorksAnsys FEAnTOPDFM / DFA

Currently applying the rear upright analysis process to the front corner, and developing test plans and generative design studies for additively manufactured titanium components driven by measured load cases.

StatusIn progress — 2027 car
FocusAM titanium, load-case driven
My roleVehicle dynamics engineer

Read the write-up →

06 · Genesis × Bambu Lab · 2026

In progress

Bambu Lab Make-athon

Program designSponsorshipBudgetingJudging rubrics

A startup makeathon hosted by Genesis, UT Austin's student-run venture fund, in which teams design and 3D-print a working prototype rather than pitching a slide deck. As lead organizer, I am responsible for the format, judging rubrics, budget, and sponsorship proposal to Bambu Lab. At the planned attendance, it would be the largest physical makeathon held at UT.

Target attendance300 students · 70–75 teams
FormatThree events · 10 finalists
My roleLead organizer

Read the write-up →

Bambu Lab Bambu Lab — anchor sponsor

03 — Contact

Hiring for Summer 2027, or want to connect?

bvt277@eid.utexas.edu

281-661-0363 · Austin, TX

Benjamin Thomas · Austin, TX Drawn and set by hand · 2026
← Projects 01 / 06

Longhorn Racing FSAE · 2025–present · Vehicle dynamics

Completed

Rear Upright

SolidWorks Ansys FEA nTOP DFM / DFA

The rear upright transmits all tire loads into the chassis. I performed finite element analysis on the assembly to locate regions of stress concentration and regions carrying negligible load.

Applying DFM and DFA principles during the redesign kept the part machinable in the team's shop. The revised upright is 5% lighter and maintains a 1.75 safety factor.

I also designed the brake line routing and associated mounting hardware, and I am currently developing test plans and generative design studies for additively manufactured titanium components driven by measured load cases.

Machined 7075-T6 rear upright rear upright — 7075-T6, as machined
Key contributions
  • Conducted finite element analysis in Ansys on the rear upright assembly to identify the stress concentrations governing component mass.
  • Revised the geometry around those regions, achieving a 5% mass reduction while maintaining the 1.75 minimum safety factor.
  • Applied DFM and DFA principles to ensure the 7075-T6 component remained manufacturable with the team's in-house equipment.
  • Designed the brake line routing and associated mounting hardware.
Gallery
Rear upright installed on the car, hub and axle boot in placeinstalled — hub, halfshaft, pushrod mount
CV boot seated against the rear uprightCV boot into the upright
Rear upright on the control arms with the chassis behindcorner assembly — upright on the A-arms
Squaring aluminum stock in a vise on a manual millsquaring stock — manual mill
Small turned aluminum part held between fingersturned part — as machined
Watching a program run on a Haas Mini MillHaas Mini Mill — program running
Ansys static structural safety factor plot of the rear uprightAnsys — safety factor, static structural
Safety factor plot, lower control arm mount of the rear uprightsafety factor — lower mount detail
Safety factor plot, upper clevis of the rear upright with min and max markerssafety factor — upper clevis detail
← All projects Next: REV GSE Cart →
← Projects 02 / 06

A&M Robotics Automation & Design Lab · Summer 2026

Completed

REV GSE Cart

SolidWorks Sheet metal Raspberry Pi FDM / SLA

A rover troubleshooting workstation designed to NASA ground-support equipment conventions: it must traverse gravel to reach the vehicle and remain legible in direct sunlight. The riveted 5052-H32 frame was developed through structural analysis of rivet loading and gusset design.

The cart carries a telemetry display and status LEDs driven by a Raspberry Pi and rides on gravel-rated casters, allowing it to be deployed wherever the rover is located.

I also developed an AI-assisted tool-scanning system that traces tool profiles and generates custom foam-insert layouts, and I managed procurement for a build of more than 100 items.

Key contributions
  • Designed a riveted 5052-H32 aluminum sheet-metal frame with gusseted joints.
  • Performed structural analysis of rivet loading and gusset sizing.
  • Integrated gravel-rated casters, a sunlight-readable telemetry display, and Raspberry Pi status indicators.
  • Developed an AI-assisted tool-scanning workflow to produce custom foam drawer inserts.
  • Managed procurement of more than 100 line items across multiple suppliers.
Gallery
Finished REV GSE cart with labeled drawersfinished cart — labeled drawers, maple panel
Powder-coated sheet metal rails with lightening patternrails — lightening pattern
Riveting the cart frameriveting the frame — uprights and gussets
Frame with drawer slides installeddrawer slides going in
Tool drawer with custom foam insertsfoam inserts — cut from scanned tool profiles
Maple side panel with pocketed triangle reliefmaple side panel — pocketed relief
Tracefinity interface showing a traced tool outline and a 3D preview of the foam insertTracefinity — traced tool profiles into an insert layout
← Prev: Rear Upright Next: 118 Manipulator →
← Projects 03 / 06

FIRST Robotics Team 118 · 2022–2025 · Student leadership

Completed

118 Manipulator

Fusion 360 CNC router Lathe SolidWorks

Over four competition seasons I worked on the manipulator subsystem, the arm and end effector responsible for acquiring and placing game pieces, with a team of eight or more students from concept through assembly.

I machined more than 30 components on the CNC router and lathe, which required designing parts that I would personally fixture and cut within a six-week build season.

These robots won a World Division Championship, two Texas District Championships, and seventeen regional and district events over that period.

Key contributions
  • Designed, machined, and assembled the manipulator subsystem across four competition seasons.
  • Manufactured more than 30 components using the CNC router and lathe.
  • Delivered each subsystem within a six-week build season alongside a team of eight or more students.
  • Served on the student leadership committee.
Gallery
CAD render of the 118 manipulator end effector and armCAD — end effector and arm assembly
Team 118 robot Firefly on the competition fieldFirefly on the field
Close-up of the arm pulleys and belt drivearm pulleys and belt drive
Robot scoring a game piece at the district championshipscoring at the district championship
Manipulator arm extended over the field structurearm at full extension
CNC router spindle inside its enclosureCNC router — spindle and enclosure
Polycarbonate plates cut on the CNC routerpolycarbonate plates off the router
prototyping video 01
prototyping video 02
← Prev: REV GSE Cart Next: World Record Chair →
← Projects 04 / 06

Personal build

In progress

World Record Chair

SolidWorks Fusion 360 CNC router

The Guinness World Records mark for the thinnest folding chair is 1.68 cm, held by Gaetano Callocchia. Teddy Garza and I have filed an attempt to surpass it with a prototype measuring under 1.27 cm when stowed, defined as the minimum distance between two parallel planes enclosing the folded chair. Whereas the current record holder's design draws on Mondrian, ours is driven by material limits: the thinnest structure that still functions as a chair.

Every component nests rather than stacks: the legs and seat retract into one another so that the folded state contains no gaps or overlapping volume. The base material, aluminum or wood, is selected on strength-to-thickness ratio, and the hinges and fasteners are custom-machined flush with the panel faces so that the laminate thickness alone determines the measurement. The chair must also stand unaided when unfolded; achieving thinness is the simpler half of the problem.

Verification is the other half. Guinness requires the chair to support at least 80 kg for ten seconds with no part of the occupant touching the ground, filmed alongside the weigh-in, together with a qualified surveyor's measurement, two independent witness statements, and a complete materials and manufacturing breakdown. The attempt is scheduled at the University of Texas at Austin for August 2026, following stress testing and witness scheduling.

Record file

CategoryThinnest folding chair
Current mark1.68 cm
Target< 1.27 cm stowed
Load test80 kg · 10 s
VenueUT Austin
AttemptAugust 2026
StatusPending evidence
Key contributions
  • Targeting a stowed thickness below 1.27 cm, compared with the current record of 1.68 cm.
  • Designing the structure to support a full adult seated load at that thickness.
  • Modeled in SolidWorks and Fusion 360; fabricated on a CNC router.
  • Guinness World Records application submitted; the attempt is scheduled at the University of Texas at Austin.
← Prev: 118 Manipulator Next: Front Upright →
← Projects 05 / 06

Longhorn Racing FSAE · 2026–present · Vehicle dynamics

In progress

Front Upright

SolidWorksAnsys FEAnTOPDFM / DFA

The front corner is the current focus. Steering loads make it a distinct problem from the rear, so I am rebuilding the load cases from logged vehicle data rather than reusing those developed for the rear.

I am conducting generative design studies in nTOP for additively manufactured titanium and comparing the printable geometry against what can be machined in house.

The next milestone is the test plan: fixture design, instrumentation, and a static pull test to validate the model before any component is installed on the vehicle.

Results and drawings will be added as the 2027 vehicle progresses.

Key contributions
  • Applying the rear upright analysis methodology to the front corner assembly.
  • Conducting generative design studies in nTOP for additively manufactured titanium components.
  • Defining load cases from measured vehicle data.
  • Authoring test plans for the 2027 vehicle.
← Prev: World Record Chair Next: Bambu Lab Make-athon →
← Projects 06 / 06

Genesis × Bambu Lab · 2026 · Lead organizer

In progress

Bambu Lab Make-athon

Program designSponsorshipBudgetingJudging rubrics

Genesis is UT Austin's student-run venture fund. I am organizing its next event as a startup makeathon in which competing teams design and 3D-print a functional product prototype rather than presenting a slide deck. Bambu Lab hardware and print resources are integrated into the format from the outset.

The competition spans three events over several weeks rather than a single weekend. Every team first pitches a concept and business case, and only the ten strongest advance to the build stage. This structure maintains judging quality and directs prize and materials funding toward the teams most likely to produce a strong result.

I authored the full program: the format and timeline, the Day 1 workshops on market validation, pitching, and CAD, separate rubrics for the concept round and the final build, the budget, and the proposal inviting Bambu Lab to serve as anchor sponsor. Prizes are awarded to every member of a winning team and teams are capped at four members, so the cost of any prize structure is known before it is committed.

Finalists build in the university makerspace's print lab rather than on personal or borrowed printers, since printer access is the most likely point of failure during the build week.

Proposal submitted to Bambu Lab · dates, rooms, and prize structure to be finalized

Bambu Lab Bambu Lab — anchor sponsor

Program file

OrganizerGenesis, UT Austin
Anchor sponsorBambu Lab
Attendance300 target
Teams70–75 · max 4 each
Finalists10
EligibilityAny university · ≥1 engineer per team
VenueUT Austin campus
Baseline budget$15,000
StatusProposal out
Key contributions
  • Designed a three-stage competition format that advances 70–75 teams to 10 finalists.
  • Authored both judging rubrics.
  • Prepared the program budget and the sponsorship proposal submitted to Bambu Lab.
  • Established the requirement that every team deliver a functional 3D-printed prototype.
Format
Day 1 — KickoffLogistics briefing, team check-in, prompt release, then the workshops, for all 70–75 teams at once.
~1 weekConcept, business case, and initial CAD. No physical build yet.
Day 2 — First pitchEvery team pitches business case and concept. Judged and narrowed to 10 finalists.
~1 weekFinalists build their prototype in the university makerspace on a per-team development budget.
Day 3 — Final pitchFinalists present a working 3D-printed product and a business case that has moved on since Day 2. Prizes awarded.
Judging

Both rubrics go out to participants on Day 1. Day 2 scores the idea and Day 3 scores the build, so the same thing is not judged twice. Novelty carries real weight instead of settling ties. A competent but unoriginal solution should score below a genuinely new approach, even if the new one is rougher.

Day 2 — concept cut

Novelty25%
Technical feasibility25%
Business viability25%
Pitch clarity15%
CAD concept quality10%

Day 3 — final

Working prototype30%
Execution quality20%
Business case refinement20%
Pitch & presentation20%
Fidelity to concept10%
← Prev: Front Upright All projects →
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