Rakesh Sivanadan

• Led the design and development of an innovative automotive closures system concept, optimizing for structural performance and manufacturing efficiency, from concept to prototype in collaboration with Materials and CAE teams. • Created surface models for sheet metal and injection-moulded components in CATIA V6 (3DX), adhering to A,B surfaces and manufacturing feasibility requirements. • Utilized SLA and FDM 3D printing, to create prototypes to verify assembly and space constraints.

• Topic-Development of a Finite Element calculation method for evaluating tolerance deviations in the mounting points of the high-voltage storage systems. • Executed Finite Element Analysis in Nastran, model setup in ANSA and post processing in Animator to validate structural integrity under geometric variations due to tolerance deviations. • Developed MATLAB-based tolerance analysis tool and automated FEM model setup workflows in ANSA Scripting Environment, reducing FEM setup time by 97%.

• Development of FEA Models and implementation of FEA Simulations of Fine Blanking Process to understand the influence of manufacturing process parameters.

• Designed locating pins for precise positioning of cell modules within the battery housing, improving assembly precision using CATIA V5. • Designed an adapter for testing a new degassing unit in the battery storage housing. • Modified test fixtures to evaluate multiple design iterations of the underbody protection plate. • Programmed a VBA tool to automate tolerance deviation analysis, reducing processing time from hours to seconds to detect recurring patterns and also eliminate human error in the process.

• Designed transit door system components and released detailed technical drawings using CREO and PTC Windchill. Built and validated kinematic simulation models of the transit door using CREO to verify functional performance. • Designed CAD Models and created Technical Drawings of fixture for Endurance Testing of Transit Door Systems and Vibration Testing of Air Reservoirs. • Bench-marking of BLDC Actuator. Performed Gear, Spring and Stack up calculations.