Work experience

Mechanical Design Engineer-Autopilot and Electronics Product Design

(Tesla) (Dec'22-Present)

• Integrated in Tesla at the Berlin Gigafactory as mechanical design engineer to work in a fast moving company with global presence

• Engineered low voltage electronic modules from concept to production, necessary for autopilot and infotainment in all Tesla vehicles (Model S/X/3/Y, Cybertruck, Cybercab and Tesla's Semi Truck)

• Delivered the mechanical design and vehicle integration of the autopilot computer, antennas such as GPS, FM radio, 4G/5G, BT, WiFi and BLE/UWB for passive door unlock, and of audio products including woofers, midrange speakers, and microphones

• Collaborated with cross-functional design teams on the architecture decisions for antenna modules in new vehicles, focusing on consolidation of modules and cost reduction while maintaining the performance

• Developed detail design of injection molded enclosures, sealed assemblies for exterior use, stamped antennas and ESD shields. Scrutinized tooling DFM, mold flow analysis, formability analysis, FAI and CpK reports from suppliers before mass production

• Spearheaded root cause analysis of field failures, working with global team as well as the suppliers to deliver 5-why chart, fishbone diagram and X-ray inspection of the PCBA. The failure was reproduced in lab test conditions, and countermeasure was identified in the mechanical fixation of the PCBA.

Engineer-chassis design

(Hero MotoCorp Ltd) (Sep'20-Nov'22)

• Led the x-functional design of plastic and sheetmetal chassis parts from concept to release for high volume 100cc motorcycle (Splendor+ and HF deluxe motorcycles), pictures shown below are for illustrative purpose only

• Realized 800g mass reduction (~7%) in the frame of a low cost commuter and validated the design over 1M durability cycles

• Pioneered meshless FEA in the team with Simsolid simulation software, reducing FEA iterations and shortening the design cycle

• Generated assembly and part drawings of production frame, swingarm, handlebar, battery holder & other structural parts

Intern-FEA

(Bloom Energy (India) Pvt Ltd) (May'18-Jul'18)

• Acoustics modelling: Developed FEA models for simulation of sound wave propagation using ABAQUS

• Simulated multiple wave-front shapes, reflection conditions and different ordered mesh elements to optimize the model

• Tested and verified the FEA model against analytical inputs