Rafael Castro

Led end-to-end connector design for high-speed automotive connectivity from concept through manufacturing, ensuring rigorous compliance with industry standards. Collaborated with global teams across signal integrity, manufacturing, and customer programs to deliver optimized technical solutions. Created 3D CAD models optimized for manufacturability, precision assembly, cost efficiency, and long-term reliability.

Led thermal management valve actuators driving portfolio growth while mentoring staff. Optimized product specs to achieve durability and NVH targets while ensuring high-volume manufacturability and cost efficiency. Redefined GD&T for critical drawings, achieving a 75% reduction in CMM inspection time and winning a Certificate of Commendation for schedule adherence. Cut prototype costs by 70% and development timing by 50% by rewriting RFQs and engineering critical testing fixtures.

Designed aftermarket diesel injection systems for heavy-duty commercial truck applications. Reverse-engineered complex electromechanical devices, establishing validated reclaim, assembly, and testing procedures. Authored comprehensive statements of work (SOW) and statements of requirements (SOR) for specialized equipment and services.

Owned full product engineering lifecycles for transfer case programs utilized across millions of GM trucks and SUVs. Led the design, development, and validation of proprietary self-locking clutch brake technology. Managed direct technical relationships with OEM design release engineers, controlling cost, timing, budgets, and team performance metrics.

Acted as primary technical interface with GM and Stellantis for axle and transfer case warranty investigations, delivering $2M in combined savings. Directed multi-site root cause analysis teams using 8D, 5-Why, and Shainin/RedX methodologies to resolve chronic field failures. Managed product design specifications and APQP deliverables for major North American and European OEM programs.

Designed electrical connectors and wire harness components for high-volume automotive OEM applications. Executed DFMEA, DVP&R, and APQP activities to support seamless product validation and manufacturing launch.

MSc Mech Eng - LCD Technology

BSc Mech Eng - minor Industrial Eng