Rajnish Kumar
Senior Mechanical Design Engineer @MAHLE
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WORK HISTORY
Senior Mechanical Design Engineer @MAHLE
Leading HVAC system design and develop new concepts based on vehicle packaging layout.Designing 2-zone and 3-zone airflow distribution using Y0 section in CAD.Validate CAD models with FEA and CFD teams for structural integrity and airflow performance.Managing cross-functional collaboration to resolve design and integration issues.Proposing technical design solutions, specifications, and validation strategies to customers.Coordinating with suppliers for prototype development using SLS soft tooling and series tooling feasibility.Validating physical prototypes for assembly fitment and conducting lab testing for performance compliance.Managing BOM, ECR/ECN, and supplier communication to meet timeline targets.Driving 15% cost reduction via feature optimization, localization, and design standardization.Releasing 3D /2D with GD & T and tolerance stack-up analysis using PLM tools.
EDUCATION
Indo-German Tool Room
Post Diploma, Tool Design and CAD/CAM.
Dr. A.P.J. Abdul Kalam Technical University
B.Tech, Manufacturing Technology.
Savitribai Phule Pune University
M.Tech, Mechanical Computer aided design Manufacturing & Engineering.
Skill-Lync
Post Graduate Program, Automotive Plastics Trim Design
ABOUT RAJNISH KUMAR
I am a proactive Automotive Mechanical Senior Design Engineer with 8.7years of experience in EV HVAC systems, engine cooling, and plastic product design. I combine strong analytical skills with a creative, solution-oriented mindset to deliver innovative automotive products. I have successfully reduced product costs by 10%, achieved 95% first-pass manufacturing yield in HVAC/cooling components, streamlined development timelines by 20% through process automation and PLM integration, and improved injection-molding efficiency by 12%.I am seeking senior mechanical design opportunities in the USA, UK, Europe, Australia, Canada, and other overseas markets where I can contribute to cutting-edge automotive projects and product innovation. Design Skills:New Product Design & Development Concept to Product DevelopmentVehicle Thermal Management System DesignHVAC & Cabin Climate Control EngineeringCabin Cooling System Design & IntegrationPlastic & Sheet Metal Product DesignDFM/DFA (Design for Manufacturing & Assembly)GD & T and Tolerance Stack-up AnalysisBill of Materials (BOM) ManagementDFMEA / FMEA / Root Cause AnalysisProduct Lifecycle Management (PLM – Teamcenter/Enovia)Supplier Coordination & Cross-functional CollaborationDesign Validation & Testing (Thermal, Airflow, Fit & Function)Basic CFD & FEA Understanding for airflow and thermal simulation CAD/CAE Skills:CAD Tools: CATIA V5, Creo, SolidWorks, AutoCADSimulation Tools: Basic knowledge of ANSYS, Moldflow, CFD (airflow, thermal)PLM Systems: Teamcenter, WindchillOffice Tools: MS Excel, Word, PowerPoint. Thanks & Regards Rajnish KumarE-mail: r••••••••@gmail.comMob. No 79••••••46\'\'Turning complex engineering challenges into innovative, efficient, and impactful solutions is my passion\'\'
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