RAHUL PATEL
NPI Manufacturing Engineer (Aerospace & Formula 1) | Reaction Engines Ltd | MSc, WMG – University of Warwick
Bengaluru
3+ years of work experience
Jun 20251 yr 3 mosAug 2026
Ballari, Karnataka, India
oLead NPI Lifecycles: Guide products from early design to final production.
oApply DFM Principles: Change part designs to reduce manufacturing costs.
oEnsure Quality Compliance: Oversee FAI testing under strict AS9100 standards.
oDirect Supplier Operations: Monitor external vendors and apply Lean methods.
Oct 20221 yr 9 mosJun 2024
Abingdon-On-Thames
● Developed and executed micromachining and assembly processes for advanced aerospace cooling system components used in high-performance thermal management applications, applying systems thinking to process design across the full assembly lifecycle.
● Led configuration management for intercooler sub-assemblies with multiple design variants — maintaining part traceability, managing engineering change orders, and ensuring BOM accuracy across concurrent configurations in an AS9100-regulated environment.
● Applied digital manufacturing principles using Delmia to simulate and validate assembly sequences before physical production, reducing risk of late-stage process changes.
● Created a Digital Twin module of a working production cell — mapping physical process parameters, equipment states, and quality control points into a virtual model to enable process monitoring and predictive analysis.
● Modelled future factory layout concepts using simulation tools to assess capacity, flow efficiency, and bottleneck elimination for scaled production of thermal management components.
● Led lean manufacturing initiative reducing cycle time for header tube production by 50% through structured process redesign — validated via Flex slim simulation prior to implementation.
● Resolved complex vacuum brazing challenges involving BNi6 paste for intricate cooling system assemblies, using systematic root cause analysis and process parameter modelling.
Oct 20221 yrSep 2023
Greater London
oManaged Aerospace Compliance: Directed AS9100 quality documentation and APQP frameworks for high-profile aerospace and motorsport clients.
oOptimized Production Paths: Defined efficient manufacturing process sequences for first article inspection (FAI), batch, and mass production runs.
oMitigated Process Risks: Developed robust PFMEAs and Control Plans to proactively catch defect risks before production launch.
oEnhanced Design Efficiency: Drove product cost reductions by executing detailed Design for Manufacturability (DFM) analyses.
oLed Digital Transformation: Contributed to Industry 4.0 and digital manufacturing initiatives to boost shop-floor productivity.
Oct 20221 yrSep 2023
● Contributed to Industry 4.0 and digital manufacturing transformation initiatives — including process digitalisation, connected shop-floor concepts, and model-based process documentation across aerospace and motorsport programmes.
● Applied MBSE principles to structure manufacturing process requirements and traceability — linking system-level design intent to manufacturing process outputs using model-based documentation approaches.
● Managed APQP for NPI programmes, including manufacturability evaluation, PFMEA, Control Plans, and FAI sign-off across aerospace and motorsport components.
● Defined manufacturing process sequences for FAI, batch, and mass production — integrating SysML-informed requirement flows to ensure design-to-production traceability.
● Drove DFM analysis and design improvement recommendations, reducing manufacturing cost and rework risk across multiple concurrent NPI programmes.
Oct 20211 yr 1 moOct 2022
Coventry, England, United Kingdom
Relevant modules :
Manufacturing Process Technology, Project Management & Control, Operations Strategy for Industry, Industrial Engineering, Virtual Factory Automation and Robotics, Advanced Materials and Processes and - Quality, Reliability & Maintenance.
o IET (The institution of Engineering and Technology) Accredited program.
o Manufacturing Engineer : Relevant module studied in the MSc are Manufacturing Process Technology, Industrial Engineering, Virtual Factory & Automation and Robotics.
o Dissertation topic: Analysis of tool wear and hole quality by conducting a comparative study between Ultrasonic Assisted Drilling (UAD) and CO2 Cryogenic drilling in Inconel ® 718 alloys fabricated by Additive Manufacturing.
o Skill: 3D experience and Dalmia for digital manufacturing, Ansys Granta 2021 for manufacturing process selection.
RAHUL’s AI Stack
Education
Master's degree, Manufacturing Systems Engineering and Management
University of Warwick
20211 yr2022
BE Mexhanical, Mechanical
R V College of Engineering, BANGALORE
20144 yrs2018
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