Mechanical Design Engineer ? Automotive & Industrial Components | CATIA V5 | Mechanical Integration | Plastic Design | Sheetmetal Design | Prototype
Aktualisiert am 21.04.2026
Profil
Freiberufler / Selbstständiger
Remote-Arbeit
Verfügbar ab: 01.05.2026
Verfügbar zu: 100%
davon vor Ort: 25%
CATIA V5
Kunststoffdesign
Automotive Design
Design for Manufacturing
Design for Assembly
GD&T
Machbarkeitsstudie
Supplier Coordination
Prototype Development
Change Request Management
SAP PLM
SAP PDM
Blech
Root Cause Analysis
Manufacturing Processes
Product Lifecycle
Fixture Design
Thermal Considerations
Validierung
Adaptive-Forward-Lighting
Tolerance Stack up
Cross functional Collaboration
D-FMEA
English
Business Fluent
German
A1 (actively improving)
Malayalam
Native

Einsatzorte

Einsatzorte

Bremen (+50km)
Deutschland
möglich

Projekte

Projekte

2 Jahre 9 Monate
2023-01 - 2025-09

Radar Frontend Electronics and Mechanics

Design Engineer CATIA V5 SAP PLM SAP PDM ...
Design Engineer
  • Developed mechanical components and assemblies for rain-light, road-condition, ice-detection, and radar sensor modules using CATIA V5
  • Designed plastic and hybrid components including housing structures, mounting systems, sealing interfaces, and packaging features for compact electronic assemblies.
  • Ensured mechanical robustness and packaging feasibility within constrained vehicle installation spaces.
  • Conducted tolerance evaluations, DFM/DFA studies, and supplier feasibility reviews to ensure manufacturable solutions.
  • Collaborated with electronics, optics, CFD/thermal, validation, and manufacturing teams to resolve prototype and testing issues.
  • Implemented design modifications based on validation and manufacturing feedback to ensure series production readiness.
  • Supported change management and industrialization processes in compliance with automotive standards.
Road-Condition Sensors Ice- Detection Sensors Radar Sensors Rain-Light Sensors
CATIA V5 SAP PLM SAP PDM MS Office
HELLA Fahrzeugkomponenten GmbH - 28199 Bremen, Germany
10 Jahre 7 Monate
2012-01 - 2022-07

Light Module Development

Senior Design Specialist CATIA V5 SAP PLM SAP PDM ...
Senior Design Specialist
  • Developed mechanical assemblies and structural components for light modules from RFQ through SOP.
  • Created 3D models, drawings, and GD&T definitions in CATIA V5 with documentation in SAP PLM.
  • Designed injection-molded plastic components including housings, carrier frames, optical lenses, lens holders, lighting optics, heatsinks and structural interfaces.
  • Integrated light modules with headlamp adjustment mechanisms ensuring robustness, tolerance compatibility, and reliable optical, electronic, and mechanical interfaces within packaging constraints
  • Participated in design reviews, DFMEA, and technical decision discussions to balance cost, weight, performance, and manufacturability
  • Collaborated with suppliers on tooling feasibility, part development, and manufacturing readiness
  • Supported prototype builds, validation and production trials; implemented design improvements based on test and manufacturing feedback.
  • Contributed to root cause analysis and corrective actions during development and series production phases
  • Supported change management, BOM updates, and engineering releases according to automotive development processes
  • Contributed to platform standardization initiatives, improving component reuse and reducing variant development complexity across vehicle programs.
BiLED Modules Mono LED Modules PHB Modules Matrix Beam Modules
CATIA V5 SAP PLM SAP PDM MS Office
HELLA India Automotive Private Limited, 641035 Coimbatore, India
1 Jahr
2009-08 - 2010-07

Gained hands-on exposure to manufacturing

Tool Maker ? Academic Trainee
Tool Maker ? Academic Trainee
  • Gained hands-on exposure to manufacturing and troubleshooting of injection molds, progressive tools, etc.
  • Supported tool trials, identifying and resolving manufacturing and quality issues
  • Developed understanding of process planning for machining and tool-making operations
  • Basic exposure to CNC machining, milling, turning, surface grinding, and wire cutting
  • Familiarity with electrode planning and quality inspection processes 
Larsen & Toubro Limited, 641050 Coimbatore, India

Aus- und Weiterbildung

Aus- und Weiterbildung

11 Monate
2010-08 - 2011-06

Post Graduate Diploma in Tool & Die Design

PSG Institute of Advanced Studies
PSG Institute of Advanced Studies

4 Jahre 2 Monate
2006-06 - 2010-07

Diploma in Tool and Die Engineering

Gedee Technical Training Institute
Gedee Technical Training Institute

Kompetenzen

Kompetenzen

Top-Skills

CATIA V5 Kunststoffdesign Automotive Design Design for Manufacturing Design for Assembly GD&T Machbarkeitsstudie Supplier Coordination Prototype Development Change Request Management SAP PLM SAP PDM Blech Root Cause Analysis Manufacturing Processes Product Lifecycle Fixture Design Thermal Considerations Validierung Adaptive-Forward-Lighting Tolerance Stack up Cross functional Collaboration D-FMEA

Produkte / Standards / Erfahrungen / Methoden

PROFESSIONAL SUMMARY & HIGHLIGHTS

  • Mechanical Design Engineer with 13+ years of experience in automotive product development, including 10 years of exterior lighting systems (headlamp light modules) and 3 years of sensor-related mechanical design.
  • Strong expertise in CATIA V5 3D design, plastic component design, mechanical integration, and tolerance management, across the full product lifecycle from RFQ to SOP. Experienced in regulated automotive environments, delivering robust, manufacturable, and validation-ready mechanical solutions through cross-functional collaboration. 


TECHNICAL COMPETENCIES

  • CAD & Documentation: CATIA V5 (3D modeling, assemblies, drawings, Sheetmetal), GD&T, tolerance stack-up, SAP PLM
  • Component & Module Development: Injection-molded plastic parts, housing structures, carrier frames, mounting systems, sealing concepts, heatsinks, structural interfaces
  • Integration & Packaging: Optical, electronic, and mechanical interface integration within constrained installation spaces
  • Manufacturing & Validation: DFM/DFA, DFMEA participation, supplier feasibility reviews, prototype support, validation-driven design updates, industrialization support
  • Collaboration: Cross-functional teamwork (optics, electronics, thermal/CFD, validation, manufacturing), supplier coordination, tooling coordination, change management
  • Manufacturing Knowledge: Injection molding, tooling concepts, machining basics 


SELECTED PROJECT CONTRIBUTIONS

  • Matrix Lighting Module Platform: Developed adaptable lens holder architectures enabling component reuse and reduced variant complexity.
  • Sensor Housing Mounting Optimization: Redesigned mounting interfaces to improve assembly robustness and reduce alignment deviations during validation testing.
  • MonoLED Platform Standardization: Supported component standardization initiatives to reduce tooling complexity and development effort. 


SOFTWARE & TOOLS

CATIA V5 | SAP PLM | Basic Pro-E | Basic AutoCAD | MS Office | PDM tools 

Einsatzorte

Einsatzorte

Bremen (+50km)
Deutschland
möglich

Projekte

Projekte

2 Jahre 9 Monate
2023-01 - 2025-09

Radar Frontend Electronics and Mechanics

Design Engineer CATIA V5 SAP PLM SAP PDM ...
Design Engineer
  • Developed mechanical components and assemblies for rain-light, road-condition, ice-detection, and radar sensor modules using CATIA V5
  • Designed plastic and hybrid components including housing structures, mounting systems, sealing interfaces, and packaging features for compact electronic assemblies.
  • Ensured mechanical robustness and packaging feasibility within constrained vehicle installation spaces.
  • Conducted tolerance evaluations, DFM/DFA studies, and supplier feasibility reviews to ensure manufacturable solutions.
  • Collaborated with electronics, optics, CFD/thermal, validation, and manufacturing teams to resolve prototype and testing issues.
  • Implemented design modifications based on validation and manufacturing feedback to ensure series production readiness.
  • Supported change management and industrialization processes in compliance with automotive standards.
Road-Condition Sensors Ice- Detection Sensors Radar Sensors Rain-Light Sensors
CATIA V5 SAP PLM SAP PDM MS Office
HELLA Fahrzeugkomponenten GmbH - 28199 Bremen, Germany
10 Jahre 7 Monate
2012-01 - 2022-07

Light Module Development

Senior Design Specialist CATIA V5 SAP PLM SAP PDM ...
Senior Design Specialist
  • Developed mechanical assemblies and structural components for light modules from RFQ through SOP.
  • Created 3D models, drawings, and GD&T definitions in CATIA V5 with documentation in SAP PLM.
  • Designed injection-molded plastic components including housings, carrier frames, optical lenses, lens holders, lighting optics, heatsinks and structural interfaces.
  • Integrated light modules with headlamp adjustment mechanisms ensuring robustness, tolerance compatibility, and reliable optical, electronic, and mechanical interfaces within packaging constraints
  • Participated in design reviews, DFMEA, and technical decision discussions to balance cost, weight, performance, and manufacturability
  • Collaborated with suppliers on tooling feasibility, part development, and manufacturing readiness
  • Supported prototype builds, validation and production trials; implemented design improvements based on test and manufacturing feedback.
  • Contributed to root cause analysis and corrective actions during development and series production phases
  • Supported change management, BOM updates, and engineering releases according to automotive development processes
  • Contributed to platform standardization initiatives, improving component reuse and reducing variant development complexity across vehicle programs.
BiLED Modules Mono LED Modules PHB Modules Matrix Beam Modules
CATIA V5 SAP PLM SAP PDM MS Office
HELLA India Automotive Private Limited, 641035 Coimbatore, India
1 Jahr
2009-08 - 2010-07

Gained hands-on exposure to manufacturing

Tool Maker ? Academic Trainee
Tool Maker ? Academic Trainee
  • Gained hands-on exposure to manufacturing and troubleshooting of injection molds, progressive tools, etc.
  • Supported tool trials, identifying and resolving manufacturing and quality issues
  • Developed understanding of process planning for machining and tool-making operations
  • Basic exposure to CNC machining, milling, turning, surface grinding, and wire cutting
  • Familiarity with electrode planning and quality inspection processes 
Larsen & Toubro Limited, 641050 Coimbatore, India

Aus- und Weiterbildung

Aus- und Weiterbildung

11 Monate
2010-08 - 2011-06

Post Graduate Diploma in Tool & Die Design

PSG Institute of Advanced Studies
PSG Institute of Advanced Studies

4 Jahre 2 Monate
2006-06 - 2010-07

Diploma in Tool and Die Engineering

Gedee Technical Training Institute
Gedee Technical Training Institute

Kompetenzen

Kompetenzen

Top-Skills

CATIA V5 Kunststoffdesign Automotive Design Design for Manufacturing Design for Assembly GD&T Machbarkeitsstudie Supplier Coordination Prototype Development Change Request Management SAP PLM SAP PDM Blech Root Cause Analysis Manufacturing Processes Product Lifecycle Fixture Design Thermal Considerations Validierung Adaptive-Forward-Lighting Tolerance Stack up Cross functional Collaboration D-FMEA

Produkte / Standards / Erfahrungen / Methoden

PROFESSIONAL SUMMARY & HIGHLIGHTS

  • Mechanical Design Engineer with 13+ years of experience in automotive product development, including 10 years of exterior lighting systems (headlamp light modules) and 3 years of sensor-related mechanical design.
  • Strong expertise in CATIA V5 3D design, plastic component design, mechanical integration, and tolerance management, across the full product lifecycle from RFQ to SOP. Experienced in regulated automotive environments, delivering robust, manufacturable, and validation-ready mechanical solutions through cross-functional collaboration. 


TECHNICAL COMPETENCIES

  • CAD & Documentation: CATIA V5 (3D modeling, assemblies, drawings, Sheetmetal), GD&T, tolerance stack-up, SAP PLM
  • Component & Module Development: Injection-molded plastic parts, housing structures, carrier frames, mounting systems, sealing concepts, heatsinks, structural interfaces
  • Integration & Packaging: Optical, electronic, and mechanical interface integration within constrained installation spaces
  • Manufacturing & Validation: DFM/DFA, DFMEA participation, supplier feasibility reviews, prototype support, validation-driven design updates, industrialization support
  • Collaboration: Cross-functional teamwork (optics, electronics, thermal/CFD, validation, manufacturing), supplier coordination, tooling coordination, change management
  • Manufacturing Knowledge: Injection molding, tooling concepts, machining basics 


SELECTED PROJECT CONTRIBUTIONS

  • Matrix Lighting Module Platform: Developed adaptable lens holder architectures enabling component reuse and reduced variant complexity.
  • Sensor Housing Mounting Optimization: Redesigned mounting interfaces to improve assembly robustness and reduce alignment deviations during validation testing.
  • MonoLED Platform Standardization: Supported component standardization initiatives to reduce tooling complexity and development effort. 


SOFTWARE & TOOLS

CATIA V5 | SAP PLM | Basic Pro-E | Basic AutoCAD | MS Office | PDM tools 

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