VINOTH KUMAR

Professional Summary

Highly accomplished BIW Design & Development Engineer with 13 years of comprehensive automotive experience, specializing in BIW Platform architecture, Upper Body structures, safety-critical component design, and full vehicle development cycles. Proven expertise in delivering robust, lightweight, and manufacturable BIW solutions for global automotive programs, including EV, HEV, and ICE platforms. Recognized for strong technical leadership, cross-functional collaboration, and the ability to drive design execution from concept to mass production.

Core Highlight

• 13 years of BIW design expertise spanning concept development, feasibility, packaging, TGA gates, prototype build, tooling, and SOP readiness.
• Specialized in BIW Platform architecture, including floor assemblies, rockers, pillars, cross-members, load paths, and structural reinforcement strategies.
• Strong command over Catia V5/V6 (Surface, Part, and Sheet Metal) with extensive experience in sheet-metal modeling, master sections, and complex interfaces.
• Deep understanding of global safety & crashworthiness requirements, integrating CAE inputs for frontal, side, rear, and rollover crash performance.
• Expertise in designing EV-specific safety zones, battery protection geometry, underfloor reinforcement, and intrusion control structures.
• Solid background in GD&T application, tolerance stack-up analysis, and creating production-friendly designs aligned with manufacturing capabilities.
• Experienced in DFM/DFA, stamping feasibility, welding and joining methods, hemming, fixture considerations, and tolerance management for BIW systems.
• Strong collaborative skills with CAE (Crash/NVH/Durability), manufacturing engineering, supplier teams, quality, purchasing, and program management.
• Demonstrated ability to manage engineering deliverables, design reviews, and issue closures during prototype, pilot, and mass-production phases.
• Experienced in benchmarking, cost reduction, lightweighting, and engineering change management (ECN/ECO) for design quality improvement.
• Proven leadership in team mentoring, task delegation, design validation, and supporting junior engineers with technical guidance and best practices.
• Skilled in managing RFQs, APQP processes, DFMEA reviews, and supplier coordination to ensure manufacturability and program feasibility.
• Strong problem-solving ability with a track record of resolving complex packaging, interfacing, tooling, and safety-related BIW challenges.
• Recognized for delivering high-quality, structurally optimized BIW designs aligned with safety, weight, cost, and regulatory targets.