Experience

Mahindra Automotive North America

• United States
• Motor Vehicle Manufacturing
• 200 - 300 Employee

• Senior Design Engineer/KBE/CATIA V5 technical expert

  • Oct 2017 - Present

  Assigned to chassis engineering to develop KBE Knowledgeware templates and analysis tools in CATIA V5 and advanced vehicle engineering. Developing revolutionary methods to produce tire and suspension envelopes from associated data from various suspension configurations to automatically produce smooth surface output data instead of tessellated files for suspension motion and tyre envelopes. Leading AVE design and engineering studies for electric, three and two wheeled platforms. Assigned to chassis engineering to develop KBE Knowledgeware templates and analysis tools in CATIA V5 and advanced vehicle engineering. Developing revolutionary methods to produce tire and suspension envelopes from associated data from various suspension configurations to automatically produce smooth surface output data instead of tessellated files for suspension motion and tyre envelopes. Leading AVE design and engineering studies for electric, three and two wheeled platforms.



Ford Motor Company

• United States
• Motor Vehicle Manufacturing
• 700 & Above Employee

• KBE Template developer/CATIA V5 technical expert

  • Nov 2014 - Oct 2017

  Working in digital innovation developing KBE Knowledgeware templates and CAE analysis tools using CATIA V5. Projects included developing fuel system analysis tools and a revolutionary method to visualize multiple stone impact energy to predict stone damage to underbody/components or following vehicle. Working in digital innovation developing KBE Knowledgeware templates and CAE analysis tools using CATIA V5. Projects included developing fuel system analysis tools and a revolutionary method to visualize multiple stone impact energy to predict stone damage to underbody/components or following vehicle.



Independent Contractor

• Greater Detroit Area

• Design Consultant

  • Sep 2013 - Oct 2014

  Consultant designer using CATIA V5 parametric math modeling methodology for energy storage concept. Designed manifolds, plenum chambers and backfire valves for supercharger applications. Engineered synchronous drives and tensioner pulley for an aftermarket supercharger kit. Designed aftermarket kick-start conversion kit for classic Power Bee/West Bend 820 engines. Designed mechanical fuel gauge gas cap and low tone muffler kit for generators. Consultant designer using CATIA V5 parametric math modeling methodology for energy storage concept. Designed manifolds, plenum chambers and backfire valves for supercharger applications. Engineered synchronous drives and tensioner pulley for an aftermarket supercharger kit. Designed aftermarket kick-start conversion kit for classic Power Bee/West Bend 820 engines. Designed mechanical fuel gauge gas cap and low tone muffler kit for generators.



CODA Automotive, Inc.

• United States
• Motor Vehicle Manufacturing
• 1 - 100 Employee

• Lead CAD Designer Chassis

  • Mar 2012 - Aug 2013

  Supervised the chassis CAD department, CAD data management and design assignments. Built parametrically controlled occupant package template to optimize brake pedal ratio and pedal box/master cylinder locations. Created KBE template to measure the effects of multilink rear suspension “Cam bolt” adjustment on caster and toe. Designed and optimized 15 spoke alloy wheel from concept to release. Designed and packaged various steering and suspension and components for Coda EVs. Supervised the chassis CAD department, CAD data management and design assignments. Built parametrically controlled occupant package template to optimize brake pedal ratio and pedal box/master cylinder locations. Created KBE template to measure the effects of multilink rear suspension “Cam bolt” adjustment on caster and toe. Designed and optimized 15 spoke alloy wheel from concept to release. Designed and packaged various steering and suspension and components for Coda EVs.



Fisker Inc

• United States
• Motor Vehicle Manufacturing
• 700 & Above Employee

• CATIA V5 Powertrain Designer

  • Jun 2011 - Feb 2012

  Designed castings and moldings to house high and low voltage electrical components: - front and rear inverters; auxiliary power modules, on board charge modules, solar panel boost converters and batteries. Parametrically designing plastic injection molded air induction components for the powertrain. Created trade off matrices to evaluate and optimize multiple design proposals. Packaged HV components and updated the Powertrain DMU on a regular basis. Optimized and designed stamped and fabricated brackets to concertina in crash zones. Show less



Independant Contractor

• Design Consultant

  • Jan 2011 - Jun 2011

  Developing automated fuel tank venting studies to analyse and alleviate venting problems during the design phase, 1000 times faster than current methods. Full analysis records fluid level and ventable volume data in any combination of roll, pitch and yaw in 1 degree increments, automatically producing spreadsheets and graphs from any industry standard solid CAD data. Developing automated fuel tank venting studies to analyse and alleviate venting problems during the design phase, 1000 times faster than current methods. Full analysis records fluid level and ventable volume data in any combination of roll, pitch and yaw in 1 degree increments, automatically producing spreadsheets and graphs from any industry standard solid CAD data.



Tata Technologies

• India
• IT Services and IT Consulting
• 700 & Above Employee

• Consultant Design Engineer providing CATIA V5 support to ITW Deltar and PTI

  • Jan 2010 - Dec 2010

  Parametrically designing plastic injection molded capless fuel filler for Ford, GM and Honda. Creating kinematic studies and reports to verify capless system reliability. Producing design proposals, studies and V5 drawings including GD&T for Ford and Honda. Designed injection molded components for Dodge front-grille assemblies. Developed KBE tools to automatically create “line of sight” envelopes. Parametrically designing plastic injection molded capless fuel filler for Ford, GM and Honda. Creating kinematic studies and reports to verify capless system reliability. Producing design proposals, studies and V5 drawings including GD&T for Ford and Honda. Designed injection molded components for Dodge front-grille assemblies. Developed KBE tools to automatically create “line of sight” envelopes.



INCAT Systems

• CATIA V5 instructor

  • Jun 2002 - Dec 2009

  Tutored evening classes in CATIA V5 for degners and engineers Tutored evening classes in CATIA V5 for degners and engineers



CHRYSLER contracted through INCAT Systems

• KBE Chassis Design Engineer

  • 2002 - Dec 2009

  •Specialized in study templates and CAE analysis tool development using CATIA V5. •Developed reliable multi model linking methods with embedded design rules and checks. •Documented design rules and standard operating procedures (SOP’s). •Trained, tutored and supported engineers and designers to use KBE methods and tools. •Modeled complex CAE fuel tank tolerance investigations to study the effects on rated capacity and venting efficiency for DFSS projects. •Modeled CAE/CAD simulation level sensor voltage and resistance studies to optimize pump and float location. •Developed quality control tools for studying gauge accuracy. •Developed parameter driven smart CAD models. •Developed time saving tools to automatically find fluid levels and volumes. •Developed tank strap load distribution and location optimization tools. •Validated virtual tools correlation to vehicle test/laboratory data. •Designed V5 virtual tools to study engine oil surge and pick up pipe optimization. •Produced kinematic studies of V6 engine internals. •Packaged batteries for Mercedes hybrid electric vehicles. •Developed multi model linking methods for steering gear and suspension geometry/components. •Developed parameter driven vehicle attitude charts and kinematic studies of suspension, steering, tie-rod and tire envelopes. Show less



Rolls Royce and Bentley

• Design Engineer

  • Apr 2001 - Apr 2002

  Royal limousine projects, saloon, coupe and the mid-sized Bentley (MSB). •Designed modifications to underbody, drive-train and park brake for extended wheelbase limousines. •Designed parking brake assembly for the mid-sized Bentley. •Designed foot operated park brake assembly for limousine and test vehicles. •Responsible for design and drawing of alloy wheels for Continental, Arnage and Azure. •Chassis packaging and clash detection in DMU and 4D Navigator. •Produced kinematic studies of park brake assemblies. Show less



Daewoo

• Design Engineer

  • 1998 - 2001

  •Project lead responsible for evaluating parametric and KBE functionality within CATIA V5. •Developed parameter driven steering gear packaging tools. •Developed parameter driven suspension geometry layout tools. •Developed parameter driven dynamic suspension and compliance envelopes. •Packaged steering gear, intermediate shaft and EPAS (Electric Power Assisted Steering). •Project lead responsible for evaluating parametric and KBE functionality within CATIA V5. •Developed parameter driven steering gear packaging tools. •Developed parameter driven suspension geometry layout tools. •Developed parameter driven dynamic suspension and compliance envelopes. •Packaged steering gear, intermediate shaft and EPAS (Electric Power Assisted Steering).



Auto Designs Ltd

• Manager

  • Sep 1993 - Jun 1998

  Owned and managed a small engineering company producing and designing automotive components/accessories for performance tuning and classic motor vehicle restoration. •Restored classic supercharger kits for the Mini Cooper, Austin Healey Sprite and Morris Minor. •Designed manifolds, plenum chambers and backfire valves for supercharged engines. •Developed camshafts for supercharged engine applications. •Engineered synchronous drives for superchargers. •Designed cylinder head modifications specifically for supercharged engines. •Developed large capacity; bored and stroked engines for competition and maximum power. •Developed “Straight-cut” (spur cut); close ratio “dog engagement” gear sets for racing. •Designed modifications for “Ultra light” race weight flywheels. •Developed disc brake conversion kits. •Engineered, designed and marketed adjustable ride height suspension kits for the classic Mini. •Reverse engineered various NLA Special Tuning components for historic race and rally cars. •Produced engineering reports for insurance coverage and litigation purposes. Show less



Ripspeed International Racing

• Technical expert on BMC/Leyland ‘A’ series engine and Special Tuning

  • Apr 1983 - Aug 1990

  •Technical expert on BMC/Leyland ‘A’ series engine and Special Tuning components for Mini Cooper, MG and Austin Healey Sprite. •Responsible for client communications and consultancy. •Responsible for the stock, sales and export of performance tuning accessories. •Technical expert on BMC/Leyland ‘A’ series engine and Special Tuning components for Mini Cooper, MG and Austin Healey Sprite. •Responsible for client communications and consultancy. •Responsible for the stock, sales and export of performance tuning accessories.