Headline

⚡ Staff mechanical engineer| HV Electro-Mechanical Systems | Solar Power systems, Microinverters, BESS,CCS2, MIL-DTL, PDUs | Creo/Solidworks/Inventor + ANSYS | DFM/DFA | EVs & Aerospace | BITS Pilani

About

⚡ High voltage doesn't forgive sloppy mechanical design. For 7 years, I've been the engineer teams call in before that becomes a problem — not after. I'm a Mechanical Design Engineer (M.S., BITS Pilani) who works on the parts of a system where a wrong call is expensive: connectors carrying lethal voltage, battery cabinets that can't afford a thermal event, PDUs where a tolerance error becomes a fleet-wide recall. I set the standards other engineers design against, make the call when a spec runs out, and stay accountable for a system's outcome long after the CAD is frozen — including the field failures that land back on my desk. 📐 Domains: EV Charging (CCS2, V2G) · PDUs · MIL-DTL/Aerospace Connectors · Battery Energy Storage Systems · Junction Boxes & HVIL · Swappable Battery Systems · IEC, UL, NEMA, NFPA 🛠️ Toolkit: Creo Parametric, Windchill, ANSYS Workbench | DFMEA, VAVE, RCCA, 8D | IEC 62196, MIL-DTL-38999, UL 9540A, NFPA 855 🚀 Where the judgment was tested: 🔌 TE Connectivity — Took CCS2 inlets and swappable battery connectors from concept to thousands of vehicles on the road (Mahindra, Sun Mobility); ran PDU programs for BHEL, Tata ACE, Ashok Leyland ✈️ Eaton Aerospace & Defense — Authored the design guide other engineers still build MIL-DTL-38999 connectors against; found 30% cost-out on the 8STA program without giving up a single spec 🚚 Volvo Group India — Built HVIL architecture and junction boxes for electric trucks, validated to Volvo's own bar, not just industry minimums 🔋 FIT Voltaira — Re-engineered a connector the harness team had been fighting; built the next CCS2 inlet for V2G from a blank sheet 🌞 Enphase Energy — The technical owner when IQ Battery R4 hits a field issue — RCA, second-sourcing, RMA, no exceptions. On the 80kW commercial system: own the electromechanical integration end to end — cabinet, wiring, busbars, sensors, PCB collaboration — to UL 9540A and NFPA 855 Seven years, one pattern: I get put on the systems where "close enough" isn't a real option, and I make the trade-offs between cost, manufacturability, and safety that keep them shipping anyway. 📩 Building EV, aerospace, or energy storage hardware that has to work the first time? Let's talk.

Location

Bengaluru

AI stack

claude code

claude

openai

windsurf

Work experience

Staff Mechanical Engineer at Enphase Energy, Oct 2025 - Present · 1 yr 1 mo, Bengaluru, Karnataka, India

Design And Development Engineer at Voltaira group, Dec 2024 - Sep 2025 · 10 mos, Remote

Senior Engineer - Connectors at Eaton, Mar 2024 - Dec 2024 · 10 mos, Pune District, Maharashtra, India

Manager at Volvo Group, Jan 2023 - Mar 2024 · 1 yr 3 mos, Bengaluru, Karnataka, India

R&D Product development Engineer II at TE Connectivity, Oct 2021 - Jan 2023 · 1 yr 4 mos, Pune Division, Maharashtra, India

R&D Product Development Engineer I at TE Connectivity, Jul 2019 - Sep 2021 · 2 yrs 3 mos, Pune, Maharashtra, India, Design of Power Distribution Unit (PDU) for passenger Vehicle: ▪ Study and analyse SOR from Customer ▪ Preparing the Wiring diagram as per the customer vehicle architecture ▪ Selection of electrical components such as Fuses, Contactors, Microswitches, HV connectors, LV connectors, Vent Valves etc., ▪ 3D Modelling of PDU box with finalized electrical components. ▪ Feasibility analysis concerning Manufacturing and assembly ▪ Interacting with Vendors for the bought-out parts, getting quotes required for product costing ▪ Preparing 2D drawing as per the standards and releasing the same in the Windchill PDM. ▪ Evaluation through calculation (basic), FEA simulation & prototype. ▪ Sample preparation, validation, and final product design release. Design of Swappable Battery Connector, Charge inlet & Charging gun: ▪ Study and analyse SOR from Customer ▪ Selection/ Design of Terminals, Bushes, Sealing, Fasteners, etc required for the product ▪ Designing and 3D modelling of components (sheet metal & Plastic) & sub-systems ▪ Design verification with Tolerance Stack up, Creepage & clearance analysis. ▪ Creating the BOM, detailed Engineering drawings, and releasing the drawings for manufacturing. Tool Duplication of Fuse and Relay Box (VAVE): ▪ Identification of the VALVE idea for material selection ▪ Implementation of the same with the help of the Tooling team to duplicate the existing tool to accommodate the material change ▪ Preparation of required test documents for the product validation adhering to standards and customer requirements. ▪ Preparing the samples, Visual inspection, FAIR report Inspection, and conducting Mechanical testing for the product validation ▪ Documentation of test results. ▪ Implementing the Engineering change management process ECR, ECN to identify the changes in the existing product

Education

Master's degree, Master of Engineering in Design Engineering(Mechanical), Birla Institute of Technology and Science, Pilani

Bachelor of Technology (B.Tech.), Mechanical Engineering, Regency Institute of Technology