HARI HARAN K

• Responsible for the complete integration of the motor, transmission, rear axle, and propeller shaft in the vehicle platform.
• Designed and developed transmission mounting brackets using sheet metal and die-casting methods.
• Developed a 4-point mounting system for EV transmission (600 kg class).
• Worked on horizontal and 3D inclined mounting strategies to improve structural stability and damper life.
• Conducted packaging layout, and ensured proper driveline alignment and clearances.
• Solved the middle mount damper failure issue through design modification and load redistribution.
• Coordinated with the CAE team for structural and vibration analysis validation.
• Performed DFMEA as per AIAG-VDA methodology.
• Ensured manufacturability and cost optimization of brackets.
• Supported prototype build, vehicle testing, and production release.
• Managed supplier coordination for casting and fabrication parts.

EV Transmission 3D Mounting Concept Development.

• Proposed 3D inclined mounting concept inspired by aerospace engine mounting architecture.
• Retained four isolators while modifying bracket geometry.
• Improved load distribution, and reduced damper stress concentration.
• Concepts under validation for performance enhancement.

• Designed battery structural components, including cross members, cooling plates, cell housings, and bus bars.
• Developed CAD models for cylindrical and hexagonal lithium-ion cell configurations.
• Created manufacturing drawings with GD&T, as per automotive standards.
• Performed tolerance stack-up analysis for assembly validation.
• Designed thermal porting features for coolant flow optimization.
• Maintained BOM structure, and managed CAD data in the PLM system.
• Supported prototype build and engineering change updates.
• Contributed to the development of a patented, lightweight battery cross-member concept.
• Supported CAD modeling of structurally optimized reinforcement geometry for an improved stiffness-to-weight ratio.
• Worked on a hybrid material concept, combining casting and an overmolded polymer structure.
• Assisted in manufacturability and structural validation support.

• Performed 3D modeling and 2D detailing of engine components, including the oil sump, intake manifold, and fuel injection pump bracket.
• Developed CAD models for BS VI.2-compliant diesel engine platforms.
• Supported engine packaging studies and layout optimization within vehicle constraints.
• Created manufacturing drawings with GD&T, as per engine design standards.
• Conducted tolerance stack-up analysis for mating components and assemblies.
• Updated CAD data based on prototype build feedback, and testing observations.
• Supported assembly line validation through drawing corrections, and fitment modifications.
• Implemented geometry updates for weight reduction and cost optimization.
• Maintained BOM structure, and managed CAD revisions through the PLM system.

• Designed and developed press tools, jigs, and fixtures for passenger vehicles and two-wheelers.
• Developed prototype tools for new product validation and trial production.
• Created 3D models and 2D manufacturing drawings with GD&T for production readiness.
• Performed DFMA analysis to improve manufacturability, and reduce cycle time.
• Prepared tool cost estimation, and supported supplier technical discussions.
• Coordinated with vendors for tool development, modification, and trial validation.
• Prepared and managed N1 documentation, customer submission files, and packaging standard approvals.
• Supported product development from the concept stage to production release.
• Ensured dimensional accuracy and fixture repeatability during trial and mass production.