Prasanna Kulkarni

Working in Design and development team for EV-powered vehicles as a core team member for the client, BMW Germany.

• Engineered inverter, battery (11kW/22kW), power module, DCDC converter, and PCB board layouts.
• Conducted assembly studies on electronic components including capacitors, resistors, and MOSFETs.
• Executed concept studies, simulations, and design optimizations for enhanced performance.
• Facilitated supplier and customer interactions to manage design changes effectively.
• Developed cooling channels, HV DC connectors, and transformers for improved efficiency.
• Performed clash and clearance studies to optimize assembly processes.
• Utilized CATIA V5R34 for casting casing and designing plastic isolators and sheet metal components.

• Company Overview: As the global leader, Autoliv develops, manufactures and markets protective systems, such as airbags, seatbelts, and steering wheels
• Single Stage and Dual Stage PAB (Passenger Airbag) Design and Development
• The project involved the creation of airbag modules, 3D CAD, and documentation in PLM.
• Standard parts selection for assemblies, EBOM preparation.
• Preparing the assemblies and manufacturing drawings for the same
• Creation of new revisions in case of design changes in PLM.
• 3D and 2D drawings are created according to Autoliv standards.
• Common design considerations for SS & DS modules
• Interacting with customer in case of updates, queries and coordinating with the engineers for supporting
• Airbag module interface with BIW for packaging study
• Validation of DAB cover and housing bent tab measurements.
• New ways of restricting the deviation of housing and covering interaction in the top-level assembly.
• Validating GAP and FLUSH points created already in old designs
• Interaction with supplier for verification of design
• Report generation in Excel, PowerPoint presentation, and instruction drawing creation.
• Approval process in PLM
• Customer Model with- In Car Cable Routing - Harness
• 3D parametric modeling of wiring harness for BMQ G60& G70 PAB top level of ECE and US Modules
• Input received from customer IP 3D data, old Harness module and PPT instructions
• Overall wire harness length calculation, connector, clip location fixing, avoid clash with IP
• In-vehicle and straight model 2D drawings creation as per Autoliv standards
• 3D modification in housing like convenient routing by adding bridges, ribs, slots

• Designed a casting gearbox housing which involved Gears like Spur, Bevels and Bearings etc
• Handling Structural parts of machine which involve sheet metal & casting components
• Making Tooling & fixtures for production convenience
• Preparing technical data/documents for the product released by R&D
• Testing Machines in field, Field Failure Analysis & Participation in Exhibitions
• Co-coordinating with sales and marketing team for the New or modified product requirement

• Preparation of manufacturing drawings, 3D model using Catia V5 R19, and AutoCAD software