Pavan Kumar

About Pavan Kumar

From CAD to connector, from spec sheet to serial production — I engineer what powers the future.I’m a Mechanical Design Engineer with 6+ years of experience in high-voltage electro-mechanical systems across electric vehicles, aerospace, and commercial mobility platforms. With a master’s from BITS Pilani, I apply systems thinking, cross-functional collaboration, and simulation-led validation to bring complex connector and distribution systems from concept to production. Key Domains:EV Charging (CCS2, V2G)| MIL-DTL/Aerospace Connectors | Swappable Battery Systems | Power Distribution Units (PDUs)| HVIL Loops | Junction Boxes | Thermal & Structural Design| Battery enclosures| IEC,UL,NEMA Tools & Frameworks:CAD & PLM: Creo Parametric, Windchill, TeamcenterSimulation: ANSYS Workbench, Creo SimulateStandards: IEC 62196, SAE J1772, LV 215, DFMEA, DFM/DFA, Tolerance Stack-up, VAVE, RCCA, 8D Strengths: Design-to-Manufacturing Optimization Tooling Team Integration (Injection & Stamped Parts) End-to-End Product Lifecycle Execution Validation Planning (DV/PV, DVP, Test Rig Design) Cross-functional collaboration (Design, Testing, Sourcing) Key Projects TE ConnectivityDesigned CCS2 inlets for Mahindra (IEC 62916-2/-3, SAE J1772)Developed swappable 2W/3W battery connectors (Sun Mobility)Led PDU design for BHEL, Tata ACE, and Ashok Leyland EVsRefined plastic/stamped part designs via tooling collaboration Eaton Aerospace & and Micro-MIL connector design (EN 2997, EN 3155)Authored internal design guide with materials, plating, torque formulasDelivered 30% cost savings via 8STA VAVE projectApplied DFSS: P-diagram, B-diagram, FAST Volvo Group IndiaDeveloped TVJB & IRM junction boxes for electric trucksDefined HVIL schemes, wiring harness layout, simulation reviewsBuilt validation protocols and test rigs to Volvo standards FIT VoltairaRe-engineered Nexteer PCB connector for better harness integrationCreated modular CCS2 charge inlet with V2G, sensor fusion, CharIN alignment Let’s connect if you’re building the future of mobility, and need someone who can think in millimeters, volts, and timelines—at the same time.

Experience

1. Staff Mechanical Engineer

   Enphase Energy

   Oct 2025 — Present · Bengaluru, IN

Education

• Regency Institute of Technology

  Bachelor of Technology (B.Tech.), Mechanical Engineering

  2011 — 2015

• Poornodaya Junior college

  Intermediate, Maths physics chemistry

• Birla Institute of Technology and Science, Pilani

  Master's degree, Master of Engineering in Design Engineering(Mechanical)

  2017 — 2019

• Vishwa Bharathi Public School

  Tenth Class