HEMACHANDRARAO AMPOLU
Battery Design Engineer
1-105 THATIGUDA VILLAGE GARIVIDI
Summary
- Over 6+ years in Battery pack and transmission system design for 2W, 3W, 4W automotive applications and heavy machinery.
- Proven skills in conducting research, analyzing, and interpreting counterpart specifications, technical
drawings, sketches, markups, and CAD layout data. - Core Skills: Battery architecture, thermal management, BMS integration, and transmission design
Battery Pack Calculations: Size & Capacity: Optimizing battery pack size and capacity based on energy requirements, voltage, and application needs
Structural: Calculating mechanical integrity and stress/load capacity using FEA analysis
Thermal: Modeling heat generation, dissipation, and managing temperature rise
Electrical: Performing current distribution, voltage drop, and power transfer calculations - Standards & Compliance: AIS Standards: AIS-048, AIS-156, AIS-038, AIS-037 for battery pack safety, performance, and durability
- Battery: UN 38.3, IEC 62660, ISO 12405, UL 2580, UL 1973, Plastics: UL 94, Electrical Enclosures: UL 508A, UL 50E , Busbars: IEC 60947-7-1, UL 98, Cooling: ISO 12405-1, IEC 61851, SAE J1772, Thermal Runaway: UL 1642, IEC 62133, Die Casting: ASTM B85, ISO 9001, SAE J454, Sheet Metal: ISO 9001, SAE J403 Creepage & Clearance: IEC 60950-1, IEC 60204-1
- Manufacturing Technologies: Die casting, injection molding, sheet metal bending, stamping, and machining
- Software Expertise: CATIA 3DExp, Creo, SolidWorks, ANSYS Fluent, AutoCAD
- Design Focus: Cost optimization, sustainable design, high-performing battery and transmission solutions for electric vehicles and heavy machinery
- Collaboration: Skilled in cross-functional team collaboration to deliver engineering solutions.
Overview
2025
2025
years of professional experience
6
6
years of post-secondary education
2
2
Certifications
2
2
Languages
Work History
Senior Battery Design Engineer
SEGULA Technologies
04.2024 - Current
- Design of Battery Pack for Small Commercial Vehicles (43.2 kWh), L5N (16.2 kWh), L5M (12.8 kWh) & e-Rick (6.4 kWh).
- Integration of specific voltage, capacity, and performance requirements for each vehicle type.
- Focus on energy efficiency, compact design, and operational safety in varied environmental conditions.
- Battery Pack Design & Cell Packaging Layout: Creating an efficient design for the battery pack and optimizing cell packaging for space and safety.
- Benchmarking: Comparing and evaluating various cells, modules, and packs to ensure the best fit for performance, reliability, and efficiency.
- Design Calculations: Performing detailed calculations for components such as base plates, pressure plates, cooling systems, and thermal pads to ensure optimal performance and heat management.
- Busbar Design: Ensuring that busbars are accurately designed for proper current distribution and electrical safety.
- Wiring Harness Design: Developing the wiring layout to ensure efficient power transmission and signal integrity across the system.
- Battery Disconnect Unit (BDU): Designing a safe and effective disconnect unit that enables proper battery isolation during charging and discharging.
Battery Design Engineer
Pravaig Dynamics India Pvt Ltd
05.2023 - 12.2023
- Responsible for the creation of 3D models and 2D drawings for the Injection Moulded Plastics, Extrusion, Sheet Metal & Die Casting Components for Li-Ion Battery for the Model of DEFY (90 kWh).
- Design and Development of Battery components including Battery housings, Base Plate, Bus bars, Mounting brackets, Cell Holders, Cooling tubes, Extrusion members & Pressure Plates etc.
- Selection of materials through Ashby methodology and manufacturing processes that are cost-effective and meet design requirements.
- Good technical drawing practice to create new drawings with complete part and assembly definition and Create quality, error free drawings and maintain a mutually acceptable of quality rating.
- Addressed design challenges and evaluated alternative design models to meet project requirements.
- Conducted technical evaluations of engineering designs and test results.
Senior Product Design Engineer
Motherson Technology Services Ltd
5 2022 - 12.2022
- Responsible for the creation of 3D models and 2D drawings for the Injection Molded Plastics, Die-Casting & Sheet Metal Components for 2W.
- Design and development of Battery components such as Front, Back Panels, Cell Stack, Tab Holders, Enclosures, Sealing for meeting the product requirements and physical compatibility with related sub systems, ensuring quality, cost, weight targets and product development milestones.
- Good at related tasks like GD&T, design for manufacturing (DFM) & design for assembly (DFA).
- Developed prototypes using rapid prototyping methods such as 3D printing or CNC machining for efficient validation of form, fit, and function concepts before mass production launch.
- Identified opportunities for cost reduction through material selection and process optimization, increasing profitability without compromising quality.
- Developed comprehensive design documentation, facilitating seamless transition from concept to production phase.
- Communicated with vendors and key suppliers to select project materials and meet customer needs.
Product Design Engineer
AxisCades Technologies Ltd
02.2019 - 05.2022
- Gear box with gear ratio of 22.40:1 was designed.
- Calculation of gear characteristics for manufacturing of the gears.
- Determine initial sizing for gearboxes based upon torque requirements, customer existing envelope.
- New Concept Development of Casings, Shafts, Gear pairs, bearings etc..
- Preparation of 3D models of the gear box internals, casings & assembly.
- Generation of manufacturing drawings & quality checking for casings, gear pairs & internals along with assembly drawings taking care of fits, tolerances, surface finish, materials, manufacturing process involved & other parameters.
- Carry out mechanical design work including 2D layouts, 3D CAD modelling, stress, and mechanical design calculations, FMEAs, 2D detailing, agreeing the design approach with the project Chief Designer.
Engineer Trainee
Green tech Industries Pvt Ltd
12.2017 - 12.2018
- Modification, maintenance of patterns and core boxes to reduce the defects in end castings.
- Knowledge of N.C Milling, lathe, drilling, air grinding machines.
- Knowledge of 5s principles used on floor shop & Core shop problem solving to reduce the defects in cores.
Education
Bachelor of Technology - Mechanical Engineering
GMR Institute of Technology
Srikakulam 07.2014 - 04.2017
Diploma - Mechanical Engineering
GMR Polytechnic
Visakhapatnam 08.2011 - 05.2014
SSC -
ZPH High School
Vizianagaram 06.2010 - 04.2011
Skills
Part and Product Design
Solid and Surface Modelling
Sheet Metal Design
Plastic Design
Casting
Forging
Machining Design Failure Mode and Effect Analysis (DFMEA)
Design Modification
Layout Drawings
New Concept Development
Product Lifecycle Management
Quality Review
Design Changes Recommendation GD & T
DFM
DFA
NPD
PTC Creo
ANSYS FLUENT
CFX
Space Claim
Design Modeller
Auto CAD
MS Office
CATIA 3DExp
Solidworks
2D and 3D drafting
Certification
Industry oriented course on Computational Fluid Dynamics (CFD) analysis, 2023/ R / 138, CFD Analysis of Subsonic Diffuser of Turbojet engine after Burner, CFD Analysis of Incompressible flow over air foil, CFD Analysis of Liquid cooled electronic system, CFD Analysis of Centrifugal Pump Impeller
Projects
- Study and assembly of solar inverter
- ANN for determining different parameters of different Biodiesels
- Remote Controlled Sub-Marine
- Fabrication of mini wooden lathe
Hobbies & Interests
- Hobbies: Swimming, Travelling
Disclaimer
I hereby declare that the information furnished above is true to the best of my knowledge.
Timeline
Senior Battery Design Engineer
SEGULA Technologies
04.2024 - Current
Battery Design Engineer
Pravaig Dynamics India Pvt Ltd
05.2023 - 12.2023
Industry oriented course on Computational Fluid Dynamics (CFD) analysis, 2023/ R / 138, CFD Analysis of Subsonic Diffuser of Turbojet engine after Burner, CFD Analysis of Incompressible flow over air foil, CFD Analysis of Liquid cooled electronic system, CFD Analysis of Centrifugal Pump Impeller
01-2023
Product Design Engineer
AxisCades Technologies Ltd
02.2019 - 05.2022
Engineer Trainee
Green tech Industries Pvt Ltd
12.2017 - 12.2018
PTC Creo / Pro-engineer Wildfire, ASME
09-2016
Bachelor of Technology - Mechanical Engineering
GMR Institute of Technology
07.2014 - 04.2017
Diploma - Mechanical Engineering
GMR Polytechnic
08.2011 - 05.2014
SSC -
ZPH High School
06.2010 - 04.2011
Senior Product Design Engineer
Motherson Technology Services Ltd
5 2022 - 12.2022
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