As the primary CAD owner for the VTOL concept vehicle door assemblies, I led fabrication design and integration efforts spanning composite construction, structural development, lighting systems, and manufacturing process development. I designed composite tooling and fabrication strategies for passenger-scale door structures, developing a hybrid architecture that combined a composite outer shell with an integrated metal tube-frame structure. To support precise assembly and integration, I implemented the manufacturing process in which epoxy tooling foam was bonded to composite components and subsequently re-machined to create structural locating features, hinge interfaces, and assembly datums. I also developed a door-mounted signature lighting system consisting of pinned billet aluminum components spanning approximately 3 meters in length, incorporating a continuous silicone diffuser, drape-formed acrylic lens, and tightly packaged optical features. Additionally, I developed an illuminated billet acrylic badge feature through iterative experimentation with laser etching and multi-stage finishing processes. The project required close coordination between composite fabrication, machining, structural integration, and lighting development to realize a publicly displayed VTOL concept.