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PROFESSIONAL PORTFOLIO

Federico Zanforlin

INTRODUCTION

My name is Federico Zanforlin.

Since 1995 I have been working in automotive and industrial design field.

I graduated from Polytechnics of Turin, getting my Bachelor’s Degree in Science of Architecture.

My graduation research concerned the study of calculation methods focused on controlling and reducing buildings’ energy usage.

Score: 110 with merit / 110 (the best possible score).

During my job career I acquired various experiences working with worldwide known companies

(such as FIAT-CHRYSLER GROUP, VOLKSWAGEN GROUP, ALFA ROMEO, FORD, FAW, JAC, MITSUBISHI, PININFARINA,

BERTONE, IDEA INSTITUTE, VDO MANNESMANN, MAGNETI MARELLI, BROSE, KARMANN, KAUTEX-TEXTRON,

VALEO, LEAR , ISRINGHAUSEN, ITALDESIGN, LAMBORGHINI)

which gave me the opportunity to work in multicultural and international environment,

cooperating side by side with many customers and suppliers.

Thanks to those experiences and constant training, I developed a relevant experience regarding a wide range

of industrial and automotive components design, such as:

sheet metal parts, plastic components, bumpers, seat systems, inner trims, fuel tanks, inner mirrors, outer mirrors,

retractile hard tops, kinematics linkages, dashboard panels, instrument panels, modeling of style surfaces, ergonomic studies.

Most of the companies I worked for gave me the opportunity to deal not only with engineering and style development

but also with quality and manufacturing aspects as well.

Direct collaboration with many clients and suppliers let me develop good organization and problem solving skills,

maximum attention to the customer needs and demands, strong belief on teamwork efficacy, team leading skills.

My work experiences gave me possibility to develop the knowledge of a various Cad programs such as CATIA V5 (deep knowledge),

UNIGRAPHICS NX (good knowledge), CATIA V4 (deep knowledge), AUTOCAD (good knowledge).

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GENERAL INFORMATION

PERSONAL DATA

First Name: Federico

Surname: Zanforlin

Nationality: Italian

Date of birth: 31st October 1976

Address: Via Fenoglio 21/B - Torino, Italy

Phone number: (+39)3383607822 (mobile)

E-mail: zanforlinfederico@hotmail.it

Marital status: married

EDUCATION

1995 Technical and industrial designer, Giovanni Plana High School, Torino.

Score: 60/60.

2006 I graduated from Polytechnics of Turin, getting my Bachelor’s degree in Science of Architecture.

My graduation research concerned the study of calculation methods focused on controlling

and reducing buildings’ energy usage.

Score: 110 with merit / 110.

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TRAINING

2014 Problem solving /solution finding techniques.. FIAT Training Center, Torino

2013 Project Management and Team Management. FIAT Training Center, Torino

2012 Cad software UNIGRAPHICS NX 7.5 - advanced level -FIAT Training Center, Torino.

2010 German language – basic & pre intermediate level -Academy International Institute, Venaria (Torino)

2006 Cad software CATIA V5 - advanced level - GOI Design company, Torino.

2006 Cad software CATIA V5 – basic and advanced level - Art and Crafts training centre, Torino.

2005 English language - advanced level -Polytechnics of Turin.

2004 Cad software AUTOCAD 2004 - basic and medium level - Polytechnics of Turin.

2001 Cad software UNIGRAPHICS NX - medium and advanced level - CG Progetti company, Torino.

2001 English language - technical subjects -CG Progetti company, Torino.

2000 Quality certification for engineering companies. CG Progetti company, Torino.

1995 Cad software CADDS5 and CATIAV4 - medium and advanced level - ITALDESIGN company, Torino.

LANGUAGES

Italian Mother tongue

English Good knowledge.

Dec. 2005 - P.E.T exam. Score: Pass with merit

January 2006 - I.E.L.T.S exam. Score: Advanced level

January 2013 - BULATS test. Score: C1 - Advanced level

German Basic level

Polish Basic level

COMPUTER COMPETENCE

Office Good knowledge of Word, Power Point and Excel.

Cad software Relevant knowledge of CATIA V5 and V4, good knowledge of UNIGRAPHICS.

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MAIN WORK EXPERIENCES

YEAR: 1997-1998

Job description:

Instrument panel design and engineering for Alfa Romeo vehicle

Job role:

For the German company VDO MANNESMANN I was the coordinator and responsible of the co-design activity

with ALFA ROMEO style department.

Team structure:

I had to cooperate with the supplier working team in Germany and the Alfa Romeo working team in Italy.

Target achieved:

Style & perceived quality requirements, ergonomic and optic targets, robust technical solutions.

ALFA ROMEO 147

Instrument panel of ALFA ROMEO 147 developed with the supplier

VDO MANNESMANN.

I followed the styling phase , engineering phase,

the ergonomic and optic analysis .

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YEAR: 1999

Job description:

Development and engineering of the trunk lid and hard top kinematics systems for the concept car “KARMANN COUPE”.

It has been the first coupe in the world with retractile rigid roof folded into 3 parts .

Job role:

I worked in Osnabrück (Germany) for the company KARMANN as a technical designer in team responsible for the trunk lid

and hard top development.

Team structure:

International team. Mainly composed by German and Italian engineers.

Target achieved:

The concept car has been showed to the Frankfurt Auto Show.

Karmann has developed several Patents based on this vehicle. (http://www.freepatentsonline.com/7182390.pdf)

STEP 1 STEP 2 STEP 3 STEP 4

KARMANN COUPE

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OPEN SOFT TOP

YEAR: 2000

Job description:

Windscreen crossbar and A pillar engineering , for a FORD convertible car with soft top.

Job role:

Senior Designer in the PININFARINA team, responsible for the vehicle development.

Team structure:

Mixed team between PININFARINA and other external suppliers

Target achieved:

Cross bar and A pillar with high stiffness level, able to support the roll over impact

The car reached good market success, with satisfaction of the client FORD

Windshield ring development.

Crossbar and A pillar are very slim but reaches high stiffness values

in case of vehicle rollover due to the reinforcements solution.

CLOSED SOFT TOP

FORD STREET KA

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YEAR: 2000-2003

Job description:

Design and engineering of the seats systems for DUCATO passengers version and for DUCATO commercial vehicle.

I developed the seats structure , seats foams , folding mechanism , anti-submarining system, backrest and armrest articulation system, etc.

for the German company ISRINGHAUSEN (DUCATO seats supplier)

Job role:

Senior Designer/Team Leader coordinating the R&D activities of ISRINGHAUSEN ITALY

Team structure:

The team consisted of about 5-6 engineers in Italy, plus the support from the head quarter in Germany

Target achieved:

High level of seats modularity, respect of budget , weight optimization, respect of timing.

The vehicle is among the world’s best in class in terms of seats modularity, body modularity, comfort, interior space, style, running costs.

Passengers version, seats development.

Cushion, backrest , headrest, armrest design.

Commercial version,

seats development.

Seats structure, tubular design

Seat folding mechanism, in the backrest

is housed a small table and two cup holders.

FIAT DUCATO – FULL BODY FIAT DUCATO – FRONT CABIN

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YEAR: 2002-2004

April to July 2002.

Inner and outer rear mirrors design for a FIAT vehicle.

- BPROGET company, Torino -

August 2002.

Front lighting system design and modelling for VALEO company.

- VALEO lighting systems, Pianezza (Torino) -

September to December 2002.

Ergonomic study and design of a tractor seat.

- AUTOSTUDI company. Torino -

March to July 2003.

Class A style surfaces modelling of a MASERATI outer rear mirror external cover.

- BPROGET company, Torino -

January to April 2004.

Study of the FIAT PUNTO front door latch installation system and reference person for the German supplier BROSE.

- FIAT engineering centre, Torino -

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YEAR: 2004-2006

Job description:

I worked in the OASYS (JV – PININFARINA&WEBASTO) team responsible for the sealing systems, retractile roof and trunk lid development

of a MITSUBISHI convertible car.

I was involved in the Design FMEA analyzing structural calculations, dimensions and tolerances of some roof mechanical linkages.

I followed the activity until the SOP in the Bairo Canavese production plant (Turin area)

Job role:

Senior Designer. Cooperating with the style, suppliers, manufacturing.

Team structure:

The technical team consisted of about 10 engineers to develop the roof the trunk lid and the kinematic system.

Target achieved:

Good recension on the specialized magazines, excellent roof folding speed (https://www.youtube.com/watch?v=y4hyuXGT-HE),

good market feedback as a niche vehicle.

Retractile hard top engineering

and kinematic development

Rear pillar cover development

Trunk lid engineering

and kinematic development

Sealing system development

MITSUBISHI COLT CABRIO

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YEAR: 2006

Job description:

Front bumper style feasibility and engineering.

I developed the crossbar structure and positioning , license plate positioning, fog lamp installation, lower and upper grilles.

Chinese and European regulations has been taken into consideration for the crush test , lights and license plate positioning.

Job role:

Senior technical designer in PININFARINA , responsible of the front bumper engineering for the project A108-JAC

Team structure:

I coordinated a mixed team of 5-6 person composed by Italian and Moroccan engineers

Target achieved:

“Best car in Show” at the Guangzhou Motor Show 2008, very positive feedback from the market and from several specialized Chinese

magazines, record of awards won (“China New- vehicle APEAL Segment Award”,“Best Design Auto Model”, “Best Newcomer Award”,etc.).

Front bumper style support and engineering

with attention to the Chinese and European regulations.

- Development and positioning of the crush crossbar

- License plate positioning

- Fog lamp installation

- Logo installation

- Radiator air intake analysis and grille development

JAC A108

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YEAR: 2006-2007

I’ve been technical and commercial responsible at PMC, a company operating in automotive and industrial design.

The technical part of my job is mainly focused on:

- being up to date about the most developed Cad software

- being up to date about production technologies

- supporting technical clients requirements

The commercial part of my job is mainly focused on:

- customer need analysis: target costs, standards quality, project planning, etc.

- prepare appropriate technical/commercial offers

- develop the opportunity to acquire new clients

I’ve developed :

- Seat systems for ISRINGHAUSEN with focus on weight reduction solutions.

- Sun visors for FIAT 500

- Parcel shelf for ALFA ROMEO

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YEAR: 2007-2008

Job description:

Side door feasibility study and engineering. Lightweight design optimization.

Door packaging study for shipping optimization from China (components production plant) and Italy (assembly plant).

Job role:

Senior Engineer

Team structure:

Around 15 people to develop the car body, doors and external trims. Inner trims and dashboard has been developed by another company.

Target achieved:

The prototypes shown in 2013 received a very high interest from the market because of its smart technical solutions and personality.

The car will be the base for other electric vehicles development and it is possible it will reach the production phase.

ZAGATO VOLPE - ELECTRIC CAR

http://www.volpecar.com/

Innovative opening/closing solution :

Horizontal rotation axis in order to minimize the space

needed for parking and to facilitate the entry in the car

Electric compact vehicle without range limitations because it is equipped also with

a bi-fuel (natural gas and petrol) range extender which recharges the batteries.

Side door feasibility study and engineering with high focus on structural

optimization, weight reduction and packaging for shipping optimization

from China (components production plant) and Italy (assembly plant)

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YEAR: 2008-2009

Job description:

Side door feasibility study and engineering.

Excellent experience due to the fact I learned about many innovative materials and technical solutions.

Job role:

Senior Engineer/Team Leader in charge of the door development, reporting to the clients ITALDESIGN and LAMBORGHINI

Team structure:

Around 50 people to develop the whole project. Door development team consisted of 4 engineers.

Target achieved:

World wide considered as one of the most beautiful and innovative dream cars in the world,

excellent feedback from Geneva Motor Show 2011

LAMBORGHINI AVENTADOR

One of the most extreme super car in the world.

With wide use of innovative materials and technical solutions.

- Carbon fiber monocoque with Aluminum front and rear frames

- Movable spoiler and side air inlets

- Aluminum doors

Side door feasibility study and engineering:

-Development of door kinematics with horizontal axis , called Lambo Style Door

-Door in aluminum with superforming technology for the inner panel

-Supplier research for superforming technology (http://www.platinumvipuk.com)

- Position and dimension of the gas spring to help the closing/opening effort

- Glass drop development

- Door latch installation

- Door handle installation

- Side mirror installation

- Management of the doors prototype creation

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YEAR: 2010

Job description:

Side door feasibility study and engineering.

Very interesting experience due to the fact that I could directly cooperate with the style designers and with the FAW chinese team

resident in BERTONE creating an excellent collaboration.

Job role:

Senior Engineer/Team Leader in charge of the side doors development and team coordinator

Team structure:

Around 50 Italian engineers + 10 designers (from USA, UK, Italy, Brasil) + 15 Chinese resident engineers to develop the whole project.

Door development team consisted of 5 engineers.

Target achieved:

Car debut to the Shanghai Auto Show 2013, and few months later the car has been launched on the China car market

SUV vehicle for the Chinese company FAW

designed and engineered by BERTONE

Front and rear side door feasibility study and engineering:

- Direct collaboration with the style chief designer (Mike Robinson)

- Outer and inner door panel development

- Anti intrusion bar development

- Glass drop development

- Door latch installation

- Door handle installation

- Side mirror installation

- Direct and profductive cooperation with the

FAW Chinese engineering team

FAW BESTURN X80

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YEAR: 2010-2011

I’ve been involved in the feasibility phase of two BERTONE concept cars.

BERTONE PANDION has been presented in the Geneva Motor Show 2010.

Is based on the ALFA ROMEO 8C

BERTONE B99 has been presented in the Geneva Motor Show 2011.

Is based on JAGUAR chassis

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YEAR: 2011

Job description:

Packaging vehicle definition.

Body side panel engineering and team management.

Very interesting experience due to the fact that I could directly cooperate with the style designers and with the FAW Chinese

team resident in BERTONE creating an excellent collaboration.

Job role:

Team Leader in charge of the vehicle packaging and body side engineering

Team structure:

Around 40 Italian engineers + 8 designers (from USA, UK, Italy, Brasil) + 10 Chinese resident engineers to develop the whole project.

Body side panel development team consisted of 5 engineers.

Target achieved:

Very positive feedback from FAW, vehicle will be launched in 2015 on the China car market

Very luxury MPV vehicle for the Chinese company FAW

designed and engineered by BERTONE

FAW D021

- General supervision of the car and Packaging study

to define the wheelbase, front and rear overhang,

approach and departure angles , passengers space,

head envelope, door rings, overall vehicle dimensions, etc.)

- Body side panel engineering, starting from a MAZDA MPV chassis.

Very interesting activity because of the complexity of the project

and the presence of a sliding door.

- Direct and productive cooperation with the

FAW Chinese engineering team

- Direct collaboration with the style chief designer (Mike Robinson)

Management of the wind tunnel tests of the vehicle prototype

in the FIAT-CHRYSLER wind gallery

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YEAR: 2012-2013

Job description:

Front bumper style feasibility and engineering.

I developed the aesthetic parts and the structural parts of bumper assy,

and found solutions for the components installation.

External supplier team management.

Job role:

Designer Senior Specialist/Team Leader in charge of the development of two different front bumper assy versions

Team structure:

Around 8 engineers + 2 designers from USA for the front bumper engineering.

Parallel activities with suppliers, quality, cost engineering, manufacturing has been done to reach the SOP

Target achieved:

Vehicle presentation in the Geneva Motor Show 2014.

Amazing feedback from the market. Selling expectation has been strongly overpassed.

Many technical solutions has been taken also for the “sister vehicle” 500X

First JEEP SUV ever engineered and produced out of the USA.

Symbol of the successful integration between CHRYSLER (in charge of the style)

and FIAT (in charge of engineering and production)

Front bumper assy development:

- Two different lower bumper fascia development (“Street version” “Off-road version”)

- Style support

- Feasibility analysis

- Engineering solution defined to reach hi rate in EURONCAP and USNCAP

crush test and pedestrian test.

- Development and positioning of the crush crossbar

- License plate positioning for all the selling markets

- Fog lamp and DRL installation

- Radar installation

- Radiator air intake analysis and grille development

- Development of fixing solution among all the parts

(upper fascia, lower fascia, fog lamp bezel, radar bezel, lower grille, chrome inserts)

JEEP RENEGADE

STREET VERSION

OFF ROAD VERSION

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YEAR: 2014-2015

Fuel door & Fuel Housing Specialist of the whole FCA group.

My role:

- responsible of the codesign activities , through all the worldwide company projects (in Italy, Serbia, Turkey, Brasil, Poland, China)

of the fuel door & fuel housing

- co-responsible (together with my counterpart in Chrysler) of the harmonization procedures ,

between Fiat and Chrysler , of the fuel door & fuel housing bench testing.

- co-responsible (together with my counterpart in Chrysler) of the harmonization procedures ,

between Fiat and Chrysler , of the fuel door & fuel housing design rules and engineering development

I have to define and analyze:

- Fuel door position

- Gap and flush with the body side panel

- Fixing solutions

- Pivot rotation axis

- Fuel pipe cap system

- Inner reinforcement in order to reach the required stiffness and robustness

- Integrated solutions for NAFTA – EMEA – APAC –LATAM markets

- FEM calculations

- Benchmarking activity

- Bench testing reports

FUEL DOOR &HOUSING OVERVIEW

DUST INTRUSION TEST OPENING EFFORT TEST WATER MANAGEMENT TEST 19

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THANK YOU FOR YOUR KIND ATTENTION