Pushparaj Anup

CAE Engineer with 4+ years of experience in crash FE modelling, vehicle safety simulation, and structural optimisation for high-performance automotive programs. Expert in LS-Dyna (explicit solver, nonlinear dynamic FEA, material models, element formulation, time-step control, mass scaling, energy balance), HyperMesh, Oasys Primer, Lsprepost, and D3plot, with a proven track record delivering full-vehicle crash simulations (frontal, ODB, rear) across US, European, Australian, and Indian safety standards (FMVSS, Euro NCAP, IIHS, Bharat NCAP, ECE). Experienced in crash Design Verification Plan (DVP) execution, simulation-to-test correlation, and mentoring junior engineers.

Directly contributed to Mahindra vehicle programs (Be6, Thar Roxx), demonstrating deep familiarity with the OEM's engineering standards and processes. Pursuing a BSc in Data Science (IIT Madras), bringing a data-driven approach to structural and safety challenges.

Senior CAE Engineer at Magna International (2022-05 – Present)

Crash Simulation & Occupant Safety

• Created fully functional crash FE models in LS-Dyna across frontal, rear and ODB for crash DVP simulations; defined shell properties, contact interfaces, rigid bodies with distributed masses, moving deformable barriers, and boundary conditions per load case — achieving <5% peak-force deviation versus physical sled test data.
• Executed occupant safety simulations using dummy and human body models; evaluated HIC, chest deflection, and femur load injury metrics across NCAP (Euro/IIHS/Bharat) loading configurations.
• Performed quasi-static strength simulations (SBA, ISOFIX anchorage, HRP) and correlated results to regulation fixture tests, supporting ECE-R14 and FMVSS 210 compliance sign-off.
• Analysed crash behaviour to inform design improvements; collaborated with design teams to implement modifications enhancing crash performance and reducing mass — executing multiple design iterations within tight program deadlines.
• Managed mesh quality, connection methodology, and contact interface definitions for complete seat assemblies; performed rigorous energy-balance.
• Mentored junior engineers and fresh graduates in executing crash DVP simulations effectively; guided best practices in model setup, contact definitions, and post-processing to uphold simulation quality standards.
• Led project planning and prioritisation for crash simulation programs — managed resource allocation, tracked simulation milestones, and maintained adherence to program timelines while driving correlation studies between CAE and physical crash/sled test data to improve predictive accuracy.
• Collaborated closely with crash test engineers to develop test plans and test matrices, attended sled and component-level tests, and conducted post-test teardown, data analysis, and reporting.
• Delivered competent crash analysis aligned to US (FMVSS/NHTSA/IIHS), European (Euro NCAP, ECE), Australian, and Indian (Bharat NCAP) safety standards, supporting full-vehicle, system-level, and component-level evaluations.

BE in Mechanical Engineering – Pillai College of Engineering (2015 – 2019)