ANBUCHEZHIYAN J

Senior Injection Molding Simulation Engineer
Deputed to Ford Technology Services India Pvt. Ltd.
Location: [Chennai] | Duration: [9 Years]

Summary:
Seasoned CAE professional with over 10 years of experience specializing in injection molding simulation for automotive components. Proven expertise in Moldflow analysis, process optimization, and defect resolution for high-performance plastic parts used in interior and exterior vehicle systems.

Key Responsibilities & Achievements:

• Led advanced Fill, Pack, Cool, and Warp simulations using Autodesk Moldflow to validate and optimize injection molding processes for complex automotive components.
• Strategically optimized feed system architecture, cooling line layouts, and sequential gate designs in hot runner molds, significantly improving part quality and eliminating visual defects like knit lines.
• Spearheaded root cause analysis and troubleshooting for molding issues including warpage, weld lines, short shots, sink marks, and shrinkage, delivering process, material, and design-based solutions.
• Brought extensive hands-on experience in FE meshing and model setup using HyperMesh, ensuring high-quality mesh generation for accurate simulation results.
• Authored and presented detailed technical reports, correlation studies, and executive summaries to internal teams and global stakeholders, driving data-backed decision-making.
• Played a key role in correlation and validation projects, aligning simulation predictions with real-world machine trials to enhance model reliability and support production readiness.
• Actively collaborated with design, tooling, and manufacturing teams to integrate simulation insights into product development cycles, reducing lead times and rework.
• Maintained a strong track record of on-time project delivery, with a focus on quality, efficiency, and cross-functional collaboration in a fast-paced engineering environment.

CAE Engineer – FE Modeling & Injection Molding Simulation
3 Years of Experience in Automotive Plastic Component Analysis

• Performed FE modeling of plastic components including instrument panels, A/C vents, center consoles, headlamps, and other interior/exterior parts.
• Created cooling line and hot runner layouts using HyperMesh to support Moldflow simulations and thermal analysis.
• Developed FE models for door panels, chassis components, and Body-in-White (BIW) parts for structural evaluations.
• Selected suitable meshing techniques (Midplane, Dual Domain, 3D) based on part geometry and simulation needs to ensure accurate Moldflow Fill + Pack + Warp analysis.
• Assisted in identifying molding defects (e.g., warpage, weld lines, shrinkage) and proposed design or process changes for improvement.
• Delivered simulation reports and contributed to technical discussions with design and tooling teams.
• Maintained good time management and consistently met project deadlines with high-quality deliverables.