---
title: "Pavan Kumar - Staff Mechanical Engineer in Bengaluru | Tal"
description: "Meet Pavan Kumar, ⚡ 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 based in Bengaluru. AI stack includes claude code, claude, and openai."
image: "https://tal.club/meet/d-pavan-kumar/share-image"
---

# Pavan Kumar on Tal

## 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

[View the original profile](https://tal.club/meet/d-pavan-kumar)

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