Rajesh Kumar | Senior Mechanical Design Engineer at Ford Motor Company

Summary

Senior Mechanical Design EngineerFord Motor Company

Dearborn, MIJun 2021Present

Led the design and integration of powertrain components for next-generation electric vehicles, reducing part count by 18% and assembly time by 15%.
Utilized advanced FEA techniques (ANSYS) to analyze structural integrity and thermal performance, achieving a 25% improvement in component lifespan.
Managed cross-functional teams of 5 engineers to deliver design solutions on aggressive timelines, consistently meeting project milestones.
Implemented DFM/DFA principles, resulting in a 10% reduction in manufacturing costs for critical engine components.
Mentored junior engineers in CAD modeling (CATIA V5/V6) and simulation best practices, enhancing team productivity by 20%.

Mechanical Design EngineerBosch

Plymouth, MIJul 2017May 2021

Designed precision mechanical systems and components for automotive sensors, achieving a 99.8% reliability rate over 50,000 operational hours.
Performed extensive tolerance stack-up analysis and GD&T specification for complex assemblies, reducing manufacturing defects by 12%.
Collaborated with manufacturing partners to optimize component designs for high-volume production, contributing to a 5% unit cost reduction.
Developed and executed comprehensive test plans for new product validation, ensuring compliance with automotive industry standards.
Contributed to 3 successful product launches, from concept phase to mass production, exceeding performance targets by 10-15%.

EV Battery Pack Thermal Management System

Mar 2022Present

Designed and analyzed a novel cooling plate design for high-density EV battery packs, improving heat dissipation by 20% using CFD simulations.
Reduced manufacturing complexity by 15% through design consolidation, leading to a projected cost saving of $5 per battery module.
Led experimental validation of prototype thermal performance, achieving target temperature uniformity within 20C.

Autonomous Sensor Mounting System

Jan 2019Aug 2020

Developed a robust mounting system for LiDAR and camera sensors for autonomous vehicles, passing extreme vibration and environmental tests.
Optimized material selection and geometry to achieve a 25% weight reduction while maintaining structural integrity.
Collaborated with electrical and software teams to ensure seamless integration and sensor calibration accuracy.

Next-Gen Engine Component Redesign

Sep 2017Dec 2018

Redesigned a critical engine component for a 1.5L gasoline engine, resulting in a 10% reduction in overall component weight.
Performed detailed fatigue analysis using ANSYS, extending component lifespan by 30% under cyclic loading conditions.
Reduced manufacturing scrap rates by 8% through improvements in GD&T specifications and collaboration with tooling engineers.

University of Michigan - Ann ArborM.S. Mechanical Engineering

Ann Arbor, MISep 2015May 2017

Specialized in advanced mechanics and materials science with a focus on automotive applications.
Developed an optimized thermal management system for electric vehicle batteries, reducing temperature variations by 15% in simulations.
Published a thesis on fatigue life prediction for additively manufactured components.

Purdue UniversityB.S. Mechanical Engineering

West Lafayette, INSep 2011May 2015

Graduated Summa Cum Laude with a GPA of 3.9/4.0.
Awarded the Dean's Scholarship for academic excellence for four consecutive years.
Led a senior design project to develop an energy-harvesting shock absorber, achieving 20% energy recovery in lab tests.

CAD Software

CATIA V5/V6SolidWorksPTC CreoAutoCADFusion 360

CAE & Analysis

ANSYS MechanicalABAQUSNastranFEACFDThermal Analysis

Design & Engineering

DFM/DFAGD&TTolerance AnalysisPrototypingDesign ValidationMaterial Selection

Manufacturing Processes

Injection MoldingSheet Metal FabricationMachiningAdditive ManufacturingAssembly

Programming & Tools

Python (Scripting)MATLABJIRAMicrosoft ProjectSAP