Aeternum.Engineering
Aeternum Engineering · Remote Automotive Practice

Vehicle engineering,
end to end.

A remote automotive engineering practice taking electric and performance vehicles from chassis architecture, packaging and battery layout through suspension, dynamics and FEA to validated, production-ready hardware.

Led by Ali Ellithy — owning the vehicle from concept to approval: chassis and packaging, suspension and dynamics, structural FEA, and regulator-witnessed validation. The engineering breadth to lead a program, not just a subsystem.

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
Services

What I design

End-to-end vehicle engineering. I can own a whole program, architecture, packaging and battery layout through to validated hardware, or plug in on a single subsystem.

Custom chassis & suspension from a 3D scan

Send a 3D scan of your vehicle, subframe, or engine bay and I design a custom chassis, subframe, suspension mounts, or roll cage built precisely around it. Scan-to-CAD reverse engineering means the new hardware fits your actual vehicle, not a nominal one, delivered as production-ready CAD and fabrication drawings. Ideal for restomods, one-off builds, motorsport, and conversions.

Vehicle architecture & packaging

Whole-vehicle layout from the ground up, chassis architecture, component and battery-pack packaging, mass and space allocation, and the trade-offs that make a vehicle work as a system rather than a set of parts.

Suspension & vehicle dynamics

Double-wishbone and multi-link design from the hardpoints up, kinematics validated in Adams, camber, roll-centre, anti-features and bump-steer resolved against your targets.

Chassis & structural design

Tubular, ladder-frame and monocoque architectures, load-case derivation and FEA validation, and structures designed for real manufacturability and cost.

Regulatory & homologation support

Formal validation experience through DVSA/UTAC (IVA), load cases, proof factors and engineering evidence prepared and defended to the approval body.

01 — 05

Selected case studies

Work spanning full vehicles, chassis, packaging and battery systems, not one narrow subsystem. Each project covers 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 full-vehicle engineering — chassis architecture, packaging and battery layout, suspension and dynamics, structural FEA, and regulatory validation — from concept through to manufacturing. I can lead a program end to end or own a single subsystem within your team. 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.

Services: freelance suspension design · contract chassis engineering · vehicle dynamics analysis · suspension kinematics & FEA · steering system design · double-wishbone & tilting-vehicle development · regulatory component validation (IVA / type approval) · remote manufacturing supervision — for EV, micromobility and performance-vehicle startups worldwide.