Mufazzal Hussain

Result-oriented casting simulation engineer with 14 years of experience in optimizing casting processes using state-of-the-art simulation techniques and data-driven analysis.

Experienced simulation engineer / Process Engineer at Voit Automotive GmbH (2022-02 – Present)

• Lead and provide technical guidance to a team of five employees
• Implemented process optimization measures such as analysis, evaluation and improvement of existing die casting processes with a focus on quality, scrap reduction, cycle time reduction and process stability
• Reduced leakage rate of a product from approx. 25% to 2.5% within five months
• Shortened the cycle time of several products by 10s or more while maintaining quality
• Executed continuous improvement (CIP) measures, increasing mold lifetime by 20,000 cycles
• Planned, executed, and evaluated casting simulations using Magma software for optimization of filling and solidification, including temperature and stress simulations
• Derived and implemented technical measures from simulation results in collaboration with design, toolmaking, quality assurance, and production departments
• Adjusted casting concepts to reduce defects (pores, shrinkage, presolidification, delamination, etc.)
• Contributed to feasibility studies for new customer inquiries (casting concepts)
• Delivered technical presentations to customers
• Participated in investment projects, particularly analyzing semisolid processes (Rheocasting, Meltec) and 3D tempering channels (conformal cooling)
• Supervised research and development topics
• Managed and optimized manufacturing process using AI-based analysis tool, gaining hands-on experience in data-driven process optimization and automated decision support
• In-depth experience with pressure-tight components (helium and air testing) as well as laser and Friction Stir weldable casting using full-vacuum die casting molds
• Broad experience with product portfolios including gearbox components (intermediate plates 8HP), Battery housings, Airconditioning compressors, and more

Simulation Engineer and Technical Project Management at BOHAI-Trimet Automotive Holding GmbH (2013-05 – 2022-01)

• Conducted and evaluated mold-filling and solidification simulations as well as thermal cycle and stress calculations
• Optimized parameters and validated simulation results
• Presented on the topic "Optimization of a Shrinkage Cavity using Squeezer" at the Flow 3D User Meeting
• Managed research and development topics
• Provided technical customer support and project management
• Prepared technical documentation and evaluated customer inquiries (drawings, CAD, standards, specifications)
• Organized meetings and workshops with customers, suppliers, and internal departments
• Developed casting concepts and conducted feasibility studies
• Coordinated modifications of molds and trimming tools with suppliers
• Reengineered and optimized 3D data for molds and die-cast parts
• Created raw part and tool drawings
• Managed data and drawings, including IT ticket system and customer interface
• Conducted CT scans, evaluations, and defect analyses of series and prototype parts
• Extensive experience with products including valve and slider housings, oil distribution plates (8F-DCT), upper and lower housings (DL382), battery trays, and shock tower

Junior Simulation Specialist at Martinrea Honsel GmbH (2012-02 – 2013-03)

• Performed design tasks
• Created, conducted, and evaluated mold-filling and solidification simulations
• Assessed results and prepared detailed presentations

Master of Mechanical Engineering in Mechanical Engineering – Coventry University (2010-09 – 2011-11)

Bachelor of Mechanical Engineering in Mechanical Engineering – Osmania University (2005-03 – 2009-05)