Rajesh P S
Chennai
Summary
Results-oriented Mechanical Design Engineer with overall 5 years of experience in automobile product development and BIW design.
Overview
6
6
years of professional experience
1
1
Certification
Work History
Senior Executive - R&D; BIW
Montra Electric Vehicle Pvt. Ltd.
Thiruvallur
02.2025 - Current
- Led design and development of SCV <9T BIW structures.
- Experienced in detailed design of A-class surface and development
- Conducted design reviews with cross-functional teams (CFTs) ensuring manufacturability, assembly, serviceability and compliance.
- Designed for frontal impact, Roof load test & durability of the cabin.
- Executed gap & flush studies and improved them to enhance aesthetics and eliminate water leakage.
- Conducted fitment and production trials and identifying improvement areas.
- Validated part quality through PIST and CMM reports.
- Developed and documented the BIW assembly process & weld shop sequence.
- Resolved customer pain points and field issues with effective design solutions.
- Carried out higher tonnage studies using existing cabin platforms.
- Released 3D & 2D designs in PLM systems for production.
Senior Design Engineer - R&D; BIW
Daimler India Commercial Vehicle Pvt.Ltd. (Deputed by intellizign engineering service)
Kanchipuram
10.2022 - 02.2025
- Designed and optimized cabin aggregates (BIW - underbody, rear wall & Front end).
- Executed vehicle packaging, concept creation, and assembly planning.
- Localized the imported parts for cost reduction (VAVE) without compromising quality.
- Conducted vehicle-level fitment trials for functional and stationary parts.
- Resolved line issues and customer complaints, ensuring timely project delivery.
- Delivered 3D modifications, 2D drawings, BOMs, and technical documentation.
Design Engineer
Triad India Pvt. Ltd.
Chennai
06.2021 - 10.2022
- Designed and developed electrical cabins in semiconductor machines using DFM/DFA principles.
- Selected appropriate mechanical components to achieve functional requirements.
- Supported product lifecycle by collaborating with cross-functional teams.
- Delivered detailed manufacturing instructions, BOMs, and weldment cut-lists.
Engineering Trainee
Tamilnadu Petro Products Pvt. Ltd.
Chennai
10.2019 - 10.2020
Education
B.E. - Mechanical Engineering
Velammal Institute of Technology
Tamil Nadu04-2019
Skills
- Sheet metal design principles
- Spot welding and joining techniques (MIG, rivet, and adhesives)
- Design for manufacturing and assembly (DFMA)
- Solid, surface, and sheet metal 3D modeling
- Design for cost and weight reduction
- Stiffness, crash, and durability considerations
- Knowledge of ASME Y145
- Understanding of tolerances and stack-up analysis
- Understanding of CAE tools and results
- Knowledge of BIW weld fixtures and checking fixtures
- VAVE idea generation
- Knowledge in APQP and PPAP
- UG NX and CATIA Enovia
- PLM: Engineering client and team center
Projects
- Frontal impact reinforcement – designed and developed the reinforcements to withstand the frontal impact for SCV cabin as per AIS-029
- Parking brake failure: Analyzed and resolved the parking brake failure caused by the BIW structural parts
- Heavy-duty truck: rear wall: modified the design for improved manufacturability
Certification
Product Design & Development, IIT Roorkee (NPTEL)
Languages
- English, Full Professional Proficiency
- Tamil, Full Professional Proficiency
- Telugu, Full Professional Proficiency
Timeline
Senior Executive - R&D; BIW
Montra Electric Vehicle Pvt. Ltd.
02.2025 - Current
Senior Design Engineer - R&D; BIW
Daimler India Commercial Vehicle Pvt.Ltd. (Deputed by intellizign engineering service)
10.2022 - 02.2025
Design Engineer
Triad India Pvt. Ltd.
06.2021 - 10.2022
Engineering Trainee
Tamilnadu Petro Products Pvt. Ltd.
10.2019 - 10.2020
B.E. - Mechanical Engineering
Velammal Institute of Technology
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