Arpan Mandal
Lead CAE Engineer - Powertrain & Structural Castings | Ford | Manufacturing Engineer | VIT Vellore Alumni
- Role
- Lead Cae Engineer at Ford Motor Company
- Location
- Chennai, TN, IN
- LinkedIn followers
- 500 followers
About Arpan Mandal
Turning complex manufacturing challenges into optimized, data-driven solutions.” I am an R&D-focused Casting CAE Engineer at Ford Motor Company, specializing in virtual manufacturing, structural casting simulation, and tooling optimization for large structural and powertrain components, including giga castings for ICE and EV platforms. My expertise lies in developing high-fidelity, end-to-end simulation methodologies to predict distortion, thermal behavior, and defect formation across HPDC, LPDC, GDC, and GDC Tilt processes. I have engineered a structural casting simulation framework achieving ~95% correlation between CAE predictions and CMM-measured data, enabling robust design validation and right-first-time tooling decisions. I combine physics-based simulation with data-driven optimization, including the development of a machine learning–based die temperature extraction tool to improve thermal boundary condition accuracy and process robustness. Through simulation-led validation and cross-functional collaboration, I have delivered $119K+ in cost savings and reduced development lead time by ~20%. Passionate about advanced numerical simulation, structural integrity, and process innovation, I continuously strive to bridge the gap between design intent and manufacturing reality using engineering-driven decision-making.
Experience
Lead Cae Engineer
Jun 2024 — Present · Chennai, IN
Led the development of an End-to-End structural casting simulation framework for giga castings, achieving ~95% correlation between CAE predictions and CMM data. • Drove simulation-led tooling design and defect prediction for HPDC, LPDC, and GDC Tilt castings in ICE and EV components. • Implemented data-driven optimization strategies to enhance casting robustness, resulting in $119K+ in cost savings and ~20% lead-time reduction.
Education
Hooghly Engineering and Technology College 176
Bachelor of Technology - BTech
2018 — 2022
Vellore Institute of Technology
Master of Technology - MTech
2022 — 2024
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