Marcus A. Mazza, P.E. Automotive Engineer & Crash Expert

Provide technical investigations, crashworthiness and engineering, and accident reconstruction analysis.

Motor Vehicle Design, Development and Testing – from requirements, concept through validation field-testing of complete vehicles, including manufacturing. Failure Mode Effects Analysis (FMEA) for products & process and DVP&R development. Testing pre-production and production vehicles in extreme environments at or above rated capabilities. Federal Motor Vehicle Safety Standard (FMVSS) and other regulatory requirement compliance.

Motor Vehicle System Design, Development and Testing – conventional and anti-lock brakes; electronic stability control; powertrain; suspension; steering; tires; electrical; frames; and structures.

Motor Vehicle Failures – air bag; structural; suspension; axle; spindle failure and separation; wheel and bearing failure; transmission failure; sudden acceleration; cruise control; steering; frame rail; wheel separation; steering; ABS; electronic stability control; transmission; fuel injection and electronic engine controls; car, light truck and medium truck brakes; trailer hitches.

Motor Vehicle Repair – diagnosis and repair of engine, transmission, transfer case, differential and final drive, suspension and steering systems, conventional and anti-lock brake systems, stability/traction control, fuel system, emissions systems, climate control, primary and supplemental restraint systems, lighting/electrical, interior/exterior components and systems, interaction of dealers and manufacturers, and Safety Recall repairs. Proper use of service repair tools and equipment, repair procedures and shop operations.

Manufacturing Process and Equipment – hand tools, torque verification means and methods, Statistical Process Control (SPC), stamping, welding (TIG/MIG), tube bending.

Vehicle Accident Reconstruction – inspection of damaged vehicle and components. Site inspection. Review of police report, witness statements, scene photos and other documents. Computational recreation of the accident using facts and scientifically accepted methodology to determine how the accident occurred, including elements within the accident. All to determine cause(s) of the accident, including the resulting severity.

Professional Experience

Provide technical investigations, analysis, reports, and testimony toward the resolution of commercial and personal injury litigation involving vehicle collisions, vehicle crashworthiness and engineering issues, mechanical defects and malfunctions, and vehicle repair issues for passenger cars, light trucks, SUVs, medium and heavy trucks.

• Served as acting mobility team lead for six months, performing team workload planning, budgeting, management and mentoring, resulting in increased reports generation and renewed focus on methodology development and analysis tools refinement
• Vehicle dynamics and mobility specialist within the Mobility Power & Energy (MPE) Branch, providing modeling, simulation, and subject matter expertise (SME)
• Led numerous mobility analyses including: Mine Resistant Ambush Protected (MRAP), Stryker, Logistics Vehicle System Replacement (LVSR), and Joint Light Tactical Vehicle (JLTV) stability, handling and performance studies, the Stryker Analysis of Alternatives (AoA)/Business Cost Analysis (BCA) efforts, and the Rollover Detection Warning System (RDWS) studies
• Expanded modeling and simulation capabilities within the Mobility Team, which included leading a team of AMSAA mobility analysts and contractors to develop in-house Electronic Stability Control (ESC) modeling and simulation capabilities
• Developed relationships with outside organizations including the Joint Program Office (JPO) MRAP, Program Manager (PM) LVSR, PM Stryker Brigade Combat Team (SBCT), Army Research Laboratory (ARL), Army Evaluation Center (AEC), and Aberdeen Test Center (ATC), which has resulted in funding for numerous projects
• Influential in the development of the Program Executive Office (PEO) Ground Combat Systems (GCS) Campaign Plan Analysis Tool (CPAT) and Whole Systems Trade Analysis Tool (WSTAT), and involved in the WSTAT Verification, Validation and Accreditation (VV&A) effort

• Provided modeling, simulation, and SME support to the AMSAA MPE Branch
• Analyzed on-road performance of military tactical vehicles using software packages including: TruckSim, CarSim, SuspensionSim, Motion View, and Adams
• Analyzed off-road performance of military tactical vehicles and tracked vehicles using software packages including the NATO Reference Mobility Model (NRMM) and VehDyn

• Setup and managed European office at the Nuerburgring in Germany
• Solely responsible for all sales, training, service, and repair functions throughout Europe
• Setup and attended various testing and motorsports expos to help increase exposure and sales in Europe
• Assisted in software debugging and updating of machine/software manuals to meet CE standards
• Performed independent projects such as characterizing and testing the acceleration and frequency dependency of shocks
• Gained in depth knowledge of servo controlled linear/rotary drive systems and variable frequency drive (VFD) controlled rotary systems

• Designed, installed and tested complete 25,000 cfm dust collection system including; blower and baghouse, airlock and auger, ducting, fire suppression system and motor control center
• Responsible for daily operations, equipment maintenance and new equipment installation

• Co-founded MIWorks, an engineering design, prototyping, and consulting company
• Designed, constructed, and tested a motorcycle powered sports racer homologated for Sports Car Club of America (SCCA) D-Sports Racer (DSR) and C-Sports Racer (CSR)
• Modified design and sourced components for 2nd generation prototypes and production series
• Founded MITechnik in 2010, a small automotive repair shop and inspection station located in Manheim, Pennsylvania, which specialized in German cars, as part of the MIWorks family

• Oversaw the Body on Frame (BOF) Truck Platform dynamics group, insuring that their products complied with the guidelines set forth by the core group, along with all safety guidelines set forth by the government
• Supported the BOF group through simulation and testing, both on the component and full vehicle level
• Developed and evolved the guidelines which the core group upheld
• Researched and conducted independent projects which further increased the knowledge base and capabilities of the core group

ATG (Austauschgruppe)

• Selected to participate in German exchange program consisting of two six month rotations with the Mercedes car group in Stuttgart, Germany
• Completed three projects which were chosen and outlined by the core dynamics group
• Ride Comfort Tool: Built a duplicate objective ride measurement tool as used by Mercedes. Learned and translated all associated software, and developed a user manual for aid in the training of Chrysler personnel in the use of this tool
• ABS/ESP Hardware in the Loop (HIL) Test Bench: Assisted in the development of an HIL test bench, giving the core group the capability of running ABS/ESP maneuvers in their full vehicle simulations
• Active Damping Vehicle: Assisted in retrofitting a Chrysler 300C with an internally developed Mercedes-Benz active damping system, and responsible for initial tuning of the system in order to showcase the technology to the Chrysler group

CIE (Chrysler Institute of Engineering) program

• Rotated through five diverse engineering positions in two year program for new college graduates
• Newark Assembly Plant: Resident engineer responsible for all aspects of front end alignment during the second generation Durango launch
• BOF Platform Vehicle Dynamics: Assisted in the tuning of all components which affect the ride and handling for body on frame platforms
• Front Wheel Drive (FWD) Automatic Transmission: Supported the re-design and testing of front wheel drive transmission components in an effort to reduce costs as part of the material cost management (MCM) initiative
• Motorsports Chassis: Provided factory support to all Chrysler backed race teams
• Advanced Vehicle Engineering (AVE): Acted as bridge between design office and engineering, in order to insured concept and packaging feasibility of new large car platforms

Intern

• Analyzed current test procedures used in evaluating the performance and aggressivity of airbags
• Developed a model using Madymo to simulate possible new test configurations for assessing low-risk deployment airbags

Professional Credentials

• Professional Engineer: Florida, Georgia, Kansas, New Jersey, New York, North Carolina, Pennsylvania, South Carolina, Texas, Virginia
• Certified Amusement Ride Inspector, General: Commonwealth of Pennsylvania
• Certified Inspection Mechanic, Class 1: Commonwealth of Pennsylvania, 2010-2013
• Certified Emissions Inspector: Commonwealth of Pennsylvania, 2010-2012
• Defense Acquisition SPRDE-SE Level 2 Certified, 2013

Education

• Master of Science in Mechanical Engineering, University of Michigan, Dearborn, MI, May 2003
• Bachelor of Science in Mechanical Engineering, Lehigh University, Bethlehem, PA, May 2001

Continuing Education

• Point Clouds in Collision Reconstruction: Speed from Video and Crush from Photos, Lightpoint, August 2022
• Pennsylvania Amusement Ride Safety Seminar, Pennsylvania Department of Agriculture Bureaus of Ride and Measurement Standards, November 2021
• Video Evidence Training Symposium, iNPUT-ACE, June 2020
• Photogrammetry and Analysis of Digital Media, SAE International, September 2019
• Interactive Driver Response Research Program (I.DRR) Instruction, Crash Safety Solutions, August 2019
• Accident Reconstruction, The Autonomous Vehicle and ADAS, SAE International, April 2019
• Pennsylvania Amusement Ride Safety Seminar, Pennsylvania Department of Agriculture Bureaus of Ride and Measurement Standards, November 2017
• Pennsylvania Amusement Ride Safety Seminar, Pennsylvania Department of Agriculture Bureaus of Ride and Measurement Standards, March 2017
• Traffic Crash Reconstruction – 3, Northwestern University Center for Public Safety, 2016
• Traffic Crash Reconstruction – 2, Northwestern University Center for Public Safety, 2015
• Traffic Crash Reconstruction – 1, Northwestern University Center for Public Safety, 2014
• Lessons in Leadership, Business Training Works, 2013
• SPRDE-SE Level 2, Defense Acquisition University, 2012-2013
  • ACQ 201A – Intermediate Systems Acquisition, Part A
  • ACQ 201B – Intermediate Systems Acquisition, Part B
  • SYS 202 – Intermediate Systems Planning, Research, Development, and Engineering, Part I
  • SYS 203 – Intermediate Systems Planning, Research, Development, and Engineering, Part II
  • CLE 003 – Technical Reviews
• SPRDE-SE Level 1, Defense Acquisition University, 2011-2012
  • ACQ 101 – Fundamentals of Systems Acquisition Management
  • SYS 101 – Fundamentals of Systems Planning, Research, Development, and Engineering
  • CLM 017 – Risk Management
• Civilian Leader Advanced Course Phase 1, CES, 2012
• NATO Reference Mobility Model Training Workshop, MTC, 2012
• Introduction to Brake Control Systems: ABS, TSC, and ESC, SAE, 2011
• Virtual.Lab – 3D Dynamic Simulation using Multibody Simulation, LMS, 2011
• Michelin Driver Training Class: Laurens Proving Ground, Michelin Inc., 2004
• Applied Vehicle Dynamics Seminar, OptimumG, 2004
• Fundamentals of Multibody Dynamics Analysis with Adams, MSC, 2004
• MotionView/MotionSolve Intro, Altair, 2004
• GD&T Training Course, DaimlerChrysler, 2002
• Chrysler Institute for Engineering: Dealer Tech Training, DaimlerChrysler, 2001

Professional Memberships and Affiliations

• Society of Automotive Engineers (SAE), 1998-2006, 2014-present
• National Auto Sport Association (NASA), 2005-2017
• Sports Car Club of America (SCCA), 2003-present
• BMW Car Club of America, 2009-2012
• Pi Tau Sigma – Honorary Mechanical Engineering Society, 2000
• Phi Eta Sigma – National Honor Society, 1998

Patents

Vehicle Fuel Tank for Improved Crashworthiness, U.S. Patent #10000328

Publications

• Peter J. Leiss, Marcus A. Mazza, Erin M. Shipp, “Heavy Truck Fuel Storage System Design for Improved Impact Protection,” ASME Technical Paper IMECE2019-11854, 2019
• Ross Brown, Marcus Mazza, Dy Le, and Muthuvel Murugan, “Comparison of Generalized Predictive Control Algorithm Using a Full Vehicle Multi-Body Dynamics Model,” SAE Technical Paper 2012-09-24, 2012
• Marcus Mazza, Matthew Rhoads, et al, “Software-Based Electronic Stability Controller for Tactical Wheeled Vehicles,” NDIA GVSETS Technical Paper, 2012

Teaching

• Forensic Crash Course Part 2 - National Highway Traffic and Safety Administration - Office of Defects Investigation, December 2021
• ADAS and the Autonomous Vehicle - National Highway Traffic and Safety Administration - Office of Defects Investigation, May 2021
• Forensic Crash Course Part 1 - National Highway Traffic and Safety Administration - Office of Defects Investigation, April 2021

Racing Experience

Competition Race Licenses

• Waterford Hills Road Racing, Inc. (WHRRI): 2004-2006
• NASA: 2006-2016
• SCCA: 2014-2018
• ChumpCar: 2012-2015

ChumpCar

• Converted a Plymouth Neon into a ChumpCar legal racecar, 2012
• The car successfully competed in numerous endurance events, including several 24 hour enduros. 2012-2014

Spec Miata

• Built a 1.6L Spec Miata from the ground up for competition in both SCCA and NASA sanctioned events, 2006-2014
• Built a 99 Spec Miata from the ground up for competition in both SCCA and NASA sanctioned events, 2013-2016

Spec Neon

• Converted an SSC (Showroom Stock C) Neon into a Spec Neon for competition in both WHRRI and NASA sanctioned events, 2003-2006

American Viper Racing (AVR)

• Served as a volunteer mechanic and crew member for the AVR American Le Mans team, 2001

Lehigh Formula SAE Race Team

• Member of the Lehigh Formula SAE Race Team, assisting in the design and construction of Lehigh’s ’99 formula racecar, 1997-1999
• Served as Team Captain Junior and Senior years, leading the design and construction of Lehigh’s ’01 formula racecar, 1999-2001

v. 10/24/22