MOHAMMED SHAFI C.V

• Led a team of designers and toolmakers, managing full-cycle mold design from DFM, layout, and tolerance fixing to final review and delivery.
• Optimized existing designs, reducing production costs and enhancing overall performance.
• Streamlined the design process for increased efficiency by utilizing advanced CAD software tools.
• Managed multiple projects simultaneously while adhering to strict deadlines and maintaining a high level of attention to detail.
• Designed molds for automotive, electrical, connector, electronics, and home appliance applications.
• Specialized in complex mold types: 2 plate, 3 plate, hot runner, insert molding, over molding, vertical molding, loose core, collapsible core, gear mold, 2K, 3K, and gas-assisted molds.
• Utilized Siemens NX and AutoCAD to develop detailed 3D models and 2D drawings with high precision and manufacturability
• Executed tasks including electrode splitting/programming, BOM preparation, PR raising, trial attendance, and debugging.
• Solved production line mold issues and implemented cost-reduction and quality control measures through design improvements.
• Collaborated with cross-functional teams (including FAE and manufacturing) to ensure seamless production integration and document control.
• Trained and guided junior designers, optimized workflows, and improved tooling performance with a focus on reducing defects and lead time.
• Conducted research to identify and evaluate new technologies and concepts.
• Streamlined communication between engineering and manufacturing teams, facilitating smoother production transitions.
• Implemented automated systems to improve accuracy and efficiency of engineering processes.
• Solved complex design challenges, resulting in highly functional and aesthetically pleasing products.
• Brainstormed with product designers to implement and refine new manufacturing processes.
• Increased design accuracy and reduced time-to-market by implementing advanced CAD software.

• Leading plastic mold design projects for electrical products, managing DFM, layout, tolerance fixing, concept split, and full design.
• Supervising junior designers, reviewing 2D drawings, checking designs, and guiding electrode splitting and programming
• Preparing BOM, ordering standard parts, raising PRs, coordinating material procurement, and ensuring proper documentation control.
• Attending mold trials, overseeing corrections, debugging, and resolving production line mold issues efficiently.
• Cross-checking FAE reports and aligning mold design with functional and customer requirements.
• Successfully implemented design improvements that reduced production cost and improved mold performance.
• Expertise in 2 plate, 3 plate, hot runner, insert, over molding, vertical, collapsible core, gear, 2K, and gas-assisted molds.
• Skilled in Siemens NX, AutoCAD, Microsoft Office, with strong leadership, problem-solving, and cost control abilities.
• Optimized existing designs, reducing production costs and enhancing overall performance.
• Conducted technical evaluations of engineering designs and test results.
• Verified construction documentation to meet client requirements and vision.

Key Customers : General Motors, Ford, BMW, Audi, Fiat Chrysler Automobiles (FCA), Tesla, Toyota, Volvo, Daimler (Mercedes-Benz), Honda

• Led the design and development of high-precision connector molds, achieving tolerances as tight as 0.003–0.005 mm for automotive applications.
• Spearheaded mold correction and debugging activities for micro-connector molds, ensuring dimensional stability and electrical integrity under strict automotive standards.
• Resolved recurring flash, short-shot, and burn mark issues in multi-cavity connector molds by fine-tuning venting, cooling, and gate balance systems
• Collaborated with quality and tool room teams to perform root-cause analysis of tool-related failures, reducing repeat issues by 60%
• Designed electrode modifications during post-trial corrections, improving pin alignment and insert locking consistency in high-density terminal cavities.
• Actively participated in DOE (Design of Experiments) during mold trials to validate connector pin fit, retention force, and housing deformation
• Led mold improvement initiatives that enabled Aptiv to pass stringent OEM connector validation (IP sealing, pull test, thermal aging) on the first attempt.
• Worked closely with production teams to debug issues directly at the molding machine—eliminating downtime by providing real-time 3D design insights.
• Coordinated with global Aptiv teams to implement standardized connector mold debugging protocols, ensuring consistent mold performance across facilities

Key Customers: Hyundai, Kia, Maruti Suzuki, Toyota, Volkswagen, Skoda, Mahindra, Tata Motors, Renault-Nissan, Ford, Faurecia, Grupo Antolin

• Contributed to the design of large-size automotive plastic injection molds (up to 3000T) for interior and exterior components
• Worked closely with a team of two designers, handling both individual and collaborative mold design tasks.
• Prepared 2D drawings and 3D mold layouts using Siemens NX and AutoCAD, focusing on core/cavity, slider, lifter, and parting surface detailing
• Participated in DFM analysis, mold feasibility checking, and part modification discussions with senior engineers and customers.
• Attended T0/T1 trials, supported mold debugging, and addressed issues such as mismatch, flash, and cooling inefficiencies
• Followed tolerance stack-ups and applied GD&T principles to ensure accurate fit and finish of molded parts.
• Worked on molds for complex automotive trims, bumpers, door panels, and functional interior components for global OEMs.

Key Customers: ITW, GRUPO ANTOLIN, OKAY INDUSTRIES, MMM, DURA AUTO, SUNSTAR, VGUARD

• Started as a Tool Maker, later promoted to Mold Design Engineer, gaining hands-on and design expertise in automotive and electrical molds.
• Designed molds for major clients like ITW and GRUPO ANTOLIN on projects such as B552_BELL_CRANK, X308_IDH Lower, and C556_REAR_SEAT, using Siemens NX.
• Performed full mold design cycle: DFM analysis, layout, tolerance fixing, concept split, and 2D detailing
• Executed electrode splitting/ prepared accurate BOMs, STD part lists, and mold documentation.
• Attended mold trials, handled debugging and corrections, and resolved issues in production tools including CAP END FITTINGS and SWIVEL TUBE parts.
• Developed 2-plate, 3-plate, and hot runner injection molds for high-precision components using materials like PA6 GF30, POM, PP, and TPE.
• Designed over-molded and multi-cavity connector molds for OKAY INDUSTRIES, MMM, and DURA AUTO, ensuring precision and long-term tool life.
• Conducted feasibility studies, mold flow checks, and ensured compliance with customer standards and shrinkage allowances.

Brakes India, part of the TVS Group, focuses on manufacturing high-quality braking systems and related components for the automotive industry. manufacturing disc and drum brakes, brake linings, hydraulic and air brake systems, ABS for commercial vehicles, and EV braking components.

• Assisted in press tool maintenance, including die setting, sharpening, alignment, and breakdown support to ensure continuous production.
• Worked in the tool room for tool reconditioning, basic fitting, bench work, and use of surface grinding, drilling, and milling machines
• Supported the fabrication and maintenance of welding fixtures, ensuring proper clamping, tolerance holding, and ease of operator access
• Involved in the design review and assembly of jigs & fixtures used in machining and assembly operations, contributing to accuracy and repeatability
• Used measuring instruments (Vernier, micrometer, height gauge) for quality checks and tool inspection in the tool room
• Gained practical knowledge of fixture ergonomics, weld distortion control, and shop floor standards.
• Observed and supported troubleshooting activities during live production issues related to tool or fixture failures.