Tejal Aatkari

Projects: Complete Roof Assembly & Complete Front Door Assembly.

• Designed and developed BIW components including complete Roof Assembly and Front Door Assembly using CATIA V5.
• Created 3D CAD models for roof outer panel, front roof rail, rear roof rail, center roof rail, roof bows, reinforcements, and front door inner and reinforcement components.
• Developed parts by considering master sections, styling surfaces, packaging requirements, and OEM design standards.
• Performed feasibility studies to ensure manufacturability and compliance with BIW design guidelines.
• Applied GD&T (Geometric Dimensioning and Tolerancing) as per engineering drawing requirements.
• Created flange designs, embosses, beads, darts, reinforcements, reliefs, and mounting features to improve structural performance and manufacturability.
• Ensured compliance with draft angle, minimum radii, tool accessibility, and stamping feasibility during component development.
• Designed spot welds, mastic sealant, and hemming interfaces according to BIW joining requirements.
• Performed section analysis and interference checks to validate component packaging and assembly feasibility.
• Conducted design validation considering visibility, clearance, gap & flushness, and assembly requirements.
• Coordinated with styling, CAE, tooling, and manufacturing teams to incorporate design feedback.
• Managed CAD data, assembly structure, and design revisions using standard engineering practices.
• Followed DFM (Design for Manufacturing) and DFA (Design for Assembly) principles to optimize part design.
• Supported engineering change implementation and maintained design documentation throughout the project lifecycle.

• Performed sheet metal forming simulations for automotive BIW skin panels, including the D-Pillar Outer, using AutoForm.
• Conducted formability analysis to evaluate manufacturability during the early stages of product development.
• Identified and analyzed forming defects such as wrinkling, thinning, tearing, splits, excessive strain, and springback.
• Optimized process parameters including binder force, drawbead configuration, blank holding conditions, and lubrication to improve forming quality.
• Recommended design modifications to enhance part manufacturability while meeting functional and styling requirements.
• Evaluated strain distribution, thickness variation, forming limit diagrams (FLD), and material flow to validate forming feasibility.
• Performed springback analysis and supported geometry compensation to achieve dimensional accuracy after forming.
• Optimized blank shape and material utilization to reduce scrap and improve production efficiency.
• Collaborated with die design, product design, and manufacturing teams to resolve forming-related issues.
• Supported die face development by validating forming performance through simulation.
• Prepared technical reports summarizing simulation results, defect analysis, and process improvement recommendations.
• Participated in design reviews and provided simulation-based feedback to improve tooling and product quality.
• Maintained simulation documentation, engineering data, and revision records throughout the project lifecycle.
• Ensured compliance with customer specifications, OEM manufacturing standards, and quality requirements.

• Designed and developed parametric press tool assemblies using Boolean sequence methodology.
• Created die components including die block, punch, stripper, guide plate, and die set.
• Developed strip layouts considering material utilization and manufacturing feasibility.
• Designed blanking, piercing, bending, forming, and trimming die operations.
• Performed assembly validation and interference checks to ensure tool functionality.
• Prepared manufacturing drawings, BOMs, and engineering documentation.
• Coordinated with manufacturing and tooling teams to implement design modifications.
• Followed DFM principles, tooling standards, and customer specifications throughout the design process.