Rohit Kale

Automotive Design Engineer with 3 years of experience in automotive plastic component design and development. Currently working with Marelli Motherson Automotive Lighting India Pvt. Ltd., with experience in Tata Sierra DRL, Mahindra RCL Z115 & RFQs, W609 DRL, and S302 Headlamp RFQ. Proficient in CATIA V5/V6, with expertise in headlamp, rear lamp, DRL, PCB, wiring harness, and DFM design.

Design Engineer (Lighting Design) at Marelli Motherson Automotive Lighting India Pvt. Ltd. (2025-08 – Present)

• TATA SIERRA DRL
• Created 3D component data as per A-surface styling and customer requirements.
• Designed glue channels for lamp packaging and assembly.
• Created fixation proposals for proper fitment and integration.
• Prepared PCBA detail drawings and PCBA panelization data.
• Designed and integrated wire harnesses with connectors.
• Performed DFM analysis to ensure manufacturability and production feasibility.
• Managed ECN/ECR activities and incorporated design changes as per project requirements.
• Implemented design revisions and maintained updated engineering data.
• Prepared and released 2D drawings and engineering documentation as per project standards.
• MAHINDRA Z115 RCL (RFQ)
• Created concept 3D data as per A-surface styling and customer requirements.
• Created fixation proposals for fitment studies during RFQ evaluation.
• Performed lamp packaging studies using A-surface data and surrounding data as references.
• Designed wire harnesses with connectors.
• Prepared aesthetic prototype data.
• Conducted vibration-welding feasibility studies.
• Checked lamp design against design guidelines and applicable regulations.
• Coordinated project activities with global teams.
• Prepared technical presentations, TAR and BOM documentation.
• Reviewed optical and thermal simulation reports and rendering outputs.
• MAHINDRA S302 HEADLAMP (RFQ)
• Created 3D data as per A-surface styling and customer requirements.
• Designed glue channels for lamp packaging.
• Designed lamps as per design guidelines and applicable regulations.
• Designed components including light guides, light guide carriers, housings and 2K outer lenses.
• Created fully parametric 3D parts while maintaining proper design history as per customer requirements.
• Prepared technical presentations, Quality Book, TAR, BOM, DFA and DFM documentation.
• Modified 3D data based on fitment and aesthetic prototype observations.
• Reviewed optical, thermal and vibration simulation reports, mould-flow analysis and rendering outputs.
• MAHINDRA W609 DRL (RFQ)

BE Mechanical Engineering