Aeternum.Engineering
Aeternum Engineering · Remote Automotive Practice

Suspension,
steering &
vehicle dynamics.

A remote automotive engineering practice designing and validating chassis & suspension systems for electric and performance vehicles.

Led by Ali Ellithy — from first-principles kinematics to regulator-witnessed validation and remote-supervised manufacturing. Turning analytical models into vehicles that get built and approved.

See the work Start a project
Seated steer-and-tilt quad designed by Ali Ellithy Steer-to-tilt quad · shipped
5+
years in suspension & chassis design
IVA
approval won via witnessed validation
2%
parts needing CNC on a full vehicle
1:1
3D-printed monocoque, carbon-wrapped
01 — 05

Selected case studies

Each project as the problem and its constraints, the key design decisions and the reasoning behind them, how the design was validated, and what was delivered.

Road-tested seated steer-and-tilt quad
Road-tested unit under a rider — front wheels showing the simultaneous steer-and-tilt stance the project was built to achieve.
Cycleboard · 2025–2026

Seated steer-and-tilt quad

Lead design — suspension, steering & vehicle dynamics

The original was a stand-up scooter that steered by leaning — tilt drove steer. For a seated rider who can't initiate a turn by leaning, I inverted the kinematic chain: the handlebar steers the wheels through the knuckle, and the knuckle drives chassis tilt through the lower tie-rods. Tilt became an output of steering, preserving the lean-into-corner feel.

Because tilt is derived from steering on the same linkage, every geometry choice is coupled. I anchored the design by fixing tilt angle first (5°→15° per side), then resolved steering effort, handlebar range and Ackermann against it.

Bump steer < 2° 30°/20° Ackermann Double wishbone Remote-built & shipped
Genuine Mopar control arm under test in custom rig
Genuine Mopar® lower control arm in the purpose-built rig under the load applicator, instrumented for a witnessed test.
Nexuz Ltd · Technical service: UTAC

Chrysler 300C suspension validation — limousine IVA approval

Test engineer & rig designer — regulatory component validation

A Chrysler 300C limousine conversion loads the suspension beyond standard duty. To win UK IVA approval, the components needed documented evidence under the DVSA-accepted route: witnessed testing by a technical service. I designed the methodology, the rig and the instrumentation to a standard a third party would certify.

Loads were driven by a CODESYS-programmed servo actuator and verified end-to-end by calibrated load cells; deformation captured with OMEGA strain gauges in a half-bridge, logged and live-plotted in Python.

IVA approval granted 5 components · 6 tests CODESYS · load cells Strain-gauge instrumented
VOLO E1 formula-style showcase vehicle
VOLO E1 — formula-style showcase vehicle with full open-wheel suspension geometry and bodywork.
VOLO Auto Group

VOLO E1 — formula-style showcase vehicle

Lead engineer, chassis & vehicle dynamics — team leadership

A showcase vehicle built to anchor the showroom and draw investors — carrying genuinely complex suspension geometry. I led the chassis & dynamics team, owned the full front and rear suspension and wheel assemblies, and coordinated additive manufacturing, electrical, ergonomics and analysis.

I drove the manufacturing strategy so only 2% of mechanical parts required CNC, keeping cost down, and ran FEA across both chassis (a tubular frame and a 1:1 3D-printed, carbon-wrapped monocoque) plus CFD on the body.

CNC parts cut to 2% FOS ≈ 3 FEA + CFD Team lead
Modular ladder frame with MacPherson suspension
Modular ladder frame with MacPherson-strut front suspension and off-the-shelf powertrain mounts.
VOLO Auto Group

Modular ladder-frame build platform

Chassis, suspension & manufacturing design

A modular platform for vans, off-road and Jeep-inspired builds, where the defining constraint was buildability: off-the-shelf parts throughout, so the only manufacturing needed is cutting and drilling the beams — no fabrication shop required.

I chose MacPherson struts deliberately for a cost-driven modular platform, added hollow closed-tube torsional cross-bracing for stiffness at minimal weight, and verified the assembly in FEA against standard load cases including torsion.

Cut & drill only Hit cost target FEA verified DIY-documented
PyBullet 3D suspension kinematics visualization
PyBullet 3D visualization — modeled suspension motion rendered in real time, driven by the MATLAB kinematic model.
Ain Shams University · 2025

Double-wishbone kinematics & 3D visualization

Graduation project — kinematic modeling, validation & visualization

A kinematic model of a double-wishbone suspension in MATLAB — computing camber, caster, KPI, scrub, mechanical trail and roll/pitch centers through travel — then validated against MSC Adams, the industry-standard multibody package, curve by curve.

The validated motion was exported via URDF and rendered in real-time 3D in Python / PyBullet, turning an abstract kinematic model into a vehicle visibly moving on a road.

Verified vs. Adams MATLAB Python · PyBullet URDF

Let's build something that gets made.

Aeternum takes on suspension, steering, chassis and vehicle-dynamics work — from concept and analysis through validation and manufacturing supervision. Whether you're an EV or performance-vehicle startup, a converter facing regulatory testing, or building a custom platform, send a brief and you'll get a considered reply.

✉ Send a brief Upwork profile →
Aeternum Engineering · Led by Ali Ellithy · Remote, worldwide · ellithyali@gmail.com
Full project drawings, FEA/CFD figures and professional references available on request.