Rajesh Kumar Rajendran
Munich,Germany
Summary
Accomplished professional with extensive expertise in CAD software, including Catia V5/V6, 3D-Experience, UG NX, and Solid Works. Proficient in quality control tools such as GD&T, DFMEA, and tolerance stack-up analysis. Skilled in utilising PLM tools like Teamcenter-Prisma and Enovia V5 to streamline product lifecycle management. Demonstrates comprehensive material knowledge across aluminium, plastic, steel, and composites. Experienced in manufacturing processes such as injection moulding, machining, 3D printing, and composites fabrication. Adept at employing joining technologies including welding, bonding, and mechanical fasteners to ensure structural integrity.
Overview
11
11
years of professional experience
4
4
years of post-secondary education
Work history
Project Specialist Designer
RLE Mobility GmbH & Co. KG
Munich, Germany
10.2023 - 12.2025
- Upper Body Structure Design and Development
- Responsible for the development of weight-efficient automotive BIW Structural and roof parts assemblies to deliver a high level of performance through concept until SOP.
- Collaborate with attribute owners of NVH, Durability, manufacturing, prototyping, shopfloor and other departments to optimise process and design optimisations.
- Interacting with CAE teams to understand the analysis results and make design optimisation to meet the quality Requirements.
- Interact with interface modules, internal teams and external suppliers to integrate multiple systems which meet the required goals.
- Conducting design review meetings with internal teams, performing design review meetings, developing solutions, managing project timelines and workloads based on priority.
- Conduct and Lead Design review meetings with leadership teams, internal and external suppliers reviewing project timelines, cost and deliverables.
- Coordinated virtual engineering and physical validation tests to check designs meetings performance against standards.
- Performing GD&T, Tolerance stack up analysis for components at the system level and assembly level.
- Responsible for material selection and manufacturability decisions at the supplier end.
- Conduct and Lead Design review meetings with leadership teams, internal and external suppliers reviewing project timelines, cost and deliverables.
- Responsible for product release activities into PLM systems, Change request sheets and other work-related documentation.
- Vehicle Worked: BMW XNF Architecture SUV (concept – now).
Specialist Engineer
RLE India Pvt.Ltd
Bengaluru, India
01.2018 - 09.2023
- Upper Body Assembly Design and Development
- Responsible for development of weight efficient automotive BIW Structural (expertise in BSO) and roof parts assemblies to deliver high level of performance through concept until SOP.
- Developed detailed 3D model for feasibility studies (crash strength, manufacturing simulations, assembly simulations at body shop).
- Interpret CAE and manufacturing results and Develop design proposals to meet the quality standards.
- Supported extensively for the Module Taper phase of vehicle build with the usage of predecessor vehicles 3D models to match the new gen vehicles standards and build the real vehicles for tests.
- Maintain documentation and manage engineering changes through PLM systems.
- Develop engineering assembly technologies in 3D models as per the standards of BMW.
- Vehicle Worked: BMW G60 (Concept through SOP Support)
- Design and Development Closures (Decklid assembly)
- Performing Styling Feasibility Study and packaging feasibility study.
- Master section creation in consideration with flange inputs.
- Responsible for developing Detailed 3D (Tailgate trims and BIW components). Generation of assembly strategies (Welding points, Adhesives) taking in reference to the LUCID air vehicle.
- Vehicle Worked: Lucid Gravity
- Plastic Battery carrier Design and Development
- Designing of Battery carriers ensuring high strength, durability and battery safety.
- Have developed the Battery 3D model based on the Standard requirements.
- Involved in design review meetings with cross-functional teams and surrounding design stakeholders about the packaging and other development issues.
- Collaborated with material suppliers and manufacturers to select the best plastic materials, including reinforced plastics, composites, and thermal plastics.
- Conducted prototyping and testing to validate designs, ensuring compliance with automotive safety standards and customer specifications at the component level and vehicle level.
- Involved in supplier meetings for design optimisations for injection mouldings and other plastic fabrication techniques, ensuring light weight, cost effectiveness and production.
- Vehicle Worked: BMW 7 Series, 3 Series and 3 Series (China variant).
Design Engineer
Hinduja Tech Limited
Pune
06.2015 - 12.2018
- Rear Bumper and Subassembly Trim Development
- Performing a feasibility study of given input bumper styling (minimum radius check as per ECE R26 regulations, tooling direction proposal for manufacturing, and perform draft angle check). Developing parametric 3D and 2D models of components, subassemblies and complete assembly using JLR-methodology for design
- Perform packaging studies of concept design, considering the envelopes, performance and manufacturing feasibility.
- Create and maintain documentation to support product release and change management activities
- Ensure Product Lifecycle Management (PLM) system integrity and manage all product configuration data and information throughout the product lifecycle in ENOVIA.
- Vehicle Worked: JLR L551
Education
Bachelors - Mechanical Engineering
Sri Krishna College of Engineering and Technology
Coimbatore, India 06.2011 - 04.2015
Skills
- CAD-Software: Catia V5 / V6, 3D-Experience, UG NX, Solid Works
- Quality Control Tools: GD&T, DFMEA, Tolerance Stack up analysis
- PLM-Tools: Teamcenter-Prisma, Enovia V5
- Material Knowledge: Aluminum, Plastic, Steel, Composites
- Manufacturing Knowledge: Injection Moulding, Machining, 3D Printing, Composites
- Joining Technologies: Welding, Bonding, Mechanical Fasteners
Languages
Englisch – proficiency in reading and writing.
German – B1 (pursuing)
Accomplishments
- Aluminum Sill Development Developed Sill component to replace traditional steel structure taking into consideration of crash paths, material selection, assembly strategy proposal and commonization of component for different drive variants. This development helped in reduction of weight and helped in light weight construction.
- Structural Weight optimization Developed CFRTP front Roof Bow concept which improvised the rollover crashes result and reduced the weight from traditional steel by 15%.
- Enhanced Vehicle Performance Lead the Team and Developed the Torsion Ring C pillar and D pillar concept in SUV vehicle which improvised the vehicle performance.
AMG Sports Variant
- Development of Exteriors Trims (Front Bumper) components.
- Components Responsible Fog Lamp Cover, tow-eye cover & Lower Stiffener.
- Based on surrounding data provided developed the same to accommodate with in the required/desired space of packaging.
- Interaction with supplier for design feasibility and tooling feasibility
- Supported post series design and tooling changes.
Timeline
Project Specialist Designer
RLE Mobility GmbH & Co. KG
10.2023 - 12.2025
Specialist Engineer
RLE India Pvt.Ltd
01.2018 - 09.2023
Design Engineer
Hinduja Tech Limited
06.2015 - 12.2018
Bachelors - Mechanical Engineering
Sri Krishna College of Engineering and Technology
06.2011 - 04.2015