Carlos Badallo

Senior Director Vehicle Engineering at BraunAbility
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Contact Information
us****@****om
(386) 825-5501
Location
Carmel, Indiana, United States, US
Languages
  • English Native or bilingual proficiency
  • Spanish Native or bilingual proficiency

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Experience

    • United States
    • Motor Vehicle Manufacturing
    • 300 - 400 Employee
    • Senior Director Vehicle Engineering
      • Mar 2018 - Present

      • Lead the Vehicle Product Development team to produce New Vehicles and Optimize current ones by modifying or creating Floor Structures, Ramps, Doors, Suspension modifications, underbody lines, Fuel systems, Exhaust & Brake systems, to create Wheelchair Accessible Vehicles• Mentor, Inspire and Guide the Vehicle Engineering team to produce product differentiators. • Coordinate and develop vehicle conversions with integrated safety countermeasures.• Manage department budget of over $8M, performance and personnel of 60+ employees.• Collaborate in design reviews to assure all vehicle conversions are developed and engineered to meet or exceed requirements and assure product quality, timing, and cost.• Develop and tutor the team’s technical, business, and interpersonal skills.• Create tradeoff proposals with Manufacturing, Portfolio and Sales, to balance the budgets and obtain the best product.

    • Canada
    • Motor Vehicle Manufacturing
    • 700 & Above Employee
    • Global Commodity Manager - Body in White
      • Jul 2016 - Mar 2018

      • Specialist for all Body in White projects within Magna with strong technical understanding of all aspects of the commodity – product, manufacturing, and cost, creating the Strategy Documents for BIW to guide the company towards future projects and business, to help OEM reduce cost and/or weight.• Interact with OEMs, understand their needs, recognize gaps, and address them with top-of-the-line new concepts that can improve their vehicle performance and/or reduce cost and weight. • Collaborate with Steel and Aluminum suppliers on the development of new Grades.

    • United States
    • Motor Vehicle Manufacturing
    • 700 & Above Employee
    • Director of Body & Vehicle Architecture
      • Jan 2015 - Jun 2016

      • Directed a team of 3 Managers, 7 Engineers and 23 Designers for the development of the vehicle body structure, closures, and exteriors for the first Architecture that encompasses 4 different vehicles variants.• Develop timing, cost, weight, and performance targets, as well as the manufacturing strategy of the vehicle. • Create Body strategies around material selection, performance, and cost, creating a lean and efficient Body.• Design the organizational structures and business plans of the Body Engineering department.

    • United States
    • Motor Vehicle Manufacturing
    • 700 & Above Employee
    • Engineering Manager - Body Structures, Closures & Exterior
      • Apr 2013 - Dec 2014

      • Create new Body strategies for the development of the new Fisker Automotive vehicles.• Improve Cost and quality of the current Karma and develop new timing to restart production.• Re-engage all body components suppliers and obtain the best cost to assemble the vehicle within budget• Define Body Performance requirements, material specifications & gauge

    • Supervisor - Body Structures
      • Sep 2010 - Apr 2013

      • Manage a team of Engineers and Designers to develop structure concepts and integrated body solutions that meet all performance, cost, weight and safety targets to release for production and prototype over 300 body structure parts that build the next generation Plug-in Hybrid vehicle for Fisker Automotive.• Successfully led the department to achieve over $7,000,000usd in production tooling savings and over $500,000usd on the prototype development by optimizing the design and negotiating with suppliers.• Release all body components for the vehicle, follow up with suppliers and obtain the best cost.• Define Body Performance requirements, Material specifications & Heat treatment requirements• Establish welding sequence and spacing to achieve desired strength and minimize cost• Work with the supplier to manufacture and co-develop casting and forging parts and determine the machining required to achieve the shape desired at the lowest cost and reduced mass.

    • United States
    • Motor Vehicle Manufacturing
    • 700 & Above Employee
    • Lead Body Structures Designing Engineer
      • Jul 2007 - Aug 2010

      Co-chair body structure architecture reviews, managed complete math representations of integrated body solutions for advanced body in white and reduced mass 23kg by optimizing the upper structure of the current vehicle and co-developed an alternative front compartment structure reducing mass another 13kg.Assigned and Lead a team of Structural Engineers & Designers to develop structure concepts.

    • International Lead Vehicle Architecture Engineer
      • Jul 2004 - Jul 2007

      Initiated, managed and developed global best practice typical sections for the entire vehicle and co-chaired weekly global meetings with all regions to improve and obtain global agreement.Developed new global component sharing strategies while establishing and communicating hard points.International Studio Designing Engineer (Saab-Sweden) Jul, 2004-Jul, 2005Served as US liaison at SAAB Advanced Design, hosting weekly global meetings, communicating all relevant engineering decisions and styling requests to all regions.

    • Vehicle Architecture Designing Engineer
      • Jan 2001 - Jul 2004

      Served as lead vehicle configuration liaison of the hydrogen autonomy vehicle of front and rear compartments, developing total vehicle packages, performing component level studies and recommending program direction based on cost, mass, timing and other program imperatives.

    • Instrument Panel and Body Structures Designer
      • Jan 1998 - Jan 2001

      Designed and engineered vehicle interior parts and systems in GM's Global Portfolio Development Center. Validate designs using analytical tools such as Finite Element Analysis (NASTRAN) and virtual builds.

Education

  • Purdue University
    MSE, Integrated Vehicle Systems
    -
  • Instituto Politécnico Nacional
    BSE, Aeronautical Engineering
    1990 - 1995

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