Dan Hall - CV / Resume

Mechatronics Vehicle Design Engineer

03/2026 – Present

Vessev · Electric Hydrofoils · Auckland, NZ

Lead design for the thermal management architecture across high-voltage battery modules, power electronics, and cabin comfort systems using complex refrigerant and liquid cooling loops.
Integrate low-voltage PCB designs, vehicle wiring harnesses, flight sensor assemblies, and fire detection/suppression systems.
Execute component qualification and rig testing for DC-DC converters, LV energy storage, and dynamic thermal control packages under marine environments.

Development Engineering Intern – Neutron

11/2024 – 03/2026

Rocket Lab · Launch Vehicle Division · Auckland, NZ

Engineered hardware test instrumentation, custom test PCBs, and multi-channel National Instruments DAQ sensor and harness grids for Neutron stage separation mechanisms.
Executed full-scale actuation of forward fairing composite structures and validated flight-critical electromechanical actuators.
Automated telemetry processing pipelines using Python to evaluate structural load dynamics during environmental testing.

Mechanical Design Leader, Race Engineer & Europe Executive

03/2022 – 08/2026

University of Auckland Formula SAE (FSAE47) · Auckland, NZ / Europe

Curated and co-led the team’s first European Campaign in 20 years across Germany, Switzerland, and Austria, including managing logistics, carnet compliance, and budget allocation.
Achieved a global Top 10 finish at Formula Student Austria; presented chassis ergonomics and structural carbon components at Design events.
Engineered capstone carbon fibre anti-roll bar systems and nTop-optimised jacking structures verified on Instron load testing.
Facilitating trackside vehicle safety, driver training; MoTeC i2 parameter sweep testing, ECU tuning, and historical car revivals.
Undertook 3D optical scanning of gearbox profiles and performed dye fatigue analysis for health monitoring and stress verification.

Data & Race Systems Engineer

01/2023 – 02/2024

M2 Competition · Motorsport

Managed trackside telemetry pipelines across six Tatuus FT-60 open-wheelers simultaneously during the Toyota Formula Regional Oceania Championship.
Engineered mathematical MoTeC i2 performance models and custom Python data-cleansing scripts for real-time driver KPI tracking alongside Power BI.
Served as Race Engineer as part of the 2024 New Zealand Grand Prix winning team.

Data Engineer

05/2023 – 11/2023

Toyota Gazoo Racing New Zealand · Auckland, NZ

Optimised MoTeC telemetry pipelines for Tatuus FT-60 and Toyota GT86 race platforms.
Analysed combustion metrics and engine telemetry under novel fossil-free fuel configurations during track testing.

Trackside Systems Engineer & Race Technician

12/2020 – Present

Ebbett Motorsport & Mackenzie Motorsport · GT3 / GT4

Executed trackside race support, sensor diagnostics, and data analysis for McLaren 650S GT3, Lamborghini Huracán GT3, Porsche Cup, and Crawford Daytona chassis platforms.
Performed endurance racing support including damage diagnosis and pit stop operations to resolve critical mechanical issues under high-pressure scenarios.

Mechanical Restoration Technician

03/2020 – 12/2024

Autoworx Ltd · Bespoke Off-Road Builds

Executed ground-up engineering modifications on a competition 1985 Land Rover Defender 110 winch truck, including custom CAD winch bumper fabrication, engine assembly CNC waterjetting, and wiring harness construction.