Varun Agarwal
Technical Leader – Automotive CAE & Vehicle Optimization | Patented Innovations in EV Structures, NVH, and Lightweighting | AI practitioner
- Role
- Domain Consultant (Vehicle Optimization General Motors) at Tata Consultancy Services
- Location
- Bengaluru, KA, IN
- LinkedIn followers
- 500 followers
About Varun Agarwal
I am an Automotive Product Development leader with 25+ years of experience in CAE-driven…
Experience
Domain Consultant (Vehicle Optimization General Motors)
Oct 2019 — Present · Bengaluru, IN
Driving mass and performance optimization of vehicle structures and subsystems using advanced CAE methods for GM’s electric car and truck programs.Key Highlights- Developed a FRF-based global mode optimization method for improving trimmed body modes.Successfully applied across 5 vehicle programs- Led cleansheet design of interior sheet metal components, meeting modal and Head Impact Criteria (HIC) using Local Topology, Controlled Shape, and Response Surface optimization- Enhanced battery storage module design for large trucks, significantly increasing capacity and efficiency (Patent: US20•••••••49A1)- Designed innovative lattice structures for energy absorption using additive manufacturing for interior and exterior head impacts (1 patent granted: US20•••••••75; 1 filed: US20•••••••90A1)-Created the 1-step ESL optimization method, empowering CAE engineers to quickly enhance HIC performance of interior components with greater efficiency- Led optimization-driven design of the sheet metal front cradle for an electric van, executing from concept to final design using Local Topology, Section, and Gauge methods- Developed AI-driven models for EV battery laser weld inspection, segmenting defects (porosity, foil detachment, fusion) from CT scans using YOLOv11 and enabling direct abnormality prediction from 2D X-rays through paired learning.
Education
Indian Institute of Technology, Roorkee
Bachelor of Engineering (B.E.), Mechanical & Industrial Engineering Department
1992 — 1996
University of Michigan - Ann Arbor
MS, Global Manufacturing and Automotive Engineering
2007 — 2011
Skills
- Vehicle Dynamics
- Nvh
- Engineering Management
- Product Design
- Six Sigma
- Structural Optimization
- Vehicles
- Cae
- Simulations
- Automotive Engineering
- Product Development
- Engineering
- Automobile
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