Karuppaiah

Senior Design Engineer with 7 years of experience in product design, thermal systems, and new product development. Skilled in UG NX, SolidWorks, AutoCAD, Teamcenter, and SAP with expertise in DFMEA, APQP, PPAP and strong background in sheet metal, plastics, Thermal design and manufacturability-focused design.

Design Engineer - GS M&E Engineering Pte Ltd - Singapore

(2025-04)

• Designed and developed sheet metal, plastic parts, and machine components, ensuring precision, fitment, and manufacturability.
• Created and modified 3D CAD models using UG NX and SolidWorks for sheet metal, plastic, and mechanical assembly designs.
• Prepared detailed 2D fabrication drawings and assembly documentation for suppliers to support efficient manufacturing and production workflows.
• Applied Design for Manufacturability (DFM) and Design for Assembly (DFA) principles, including tolerance analysis and material selection, to optimize sheet metal and plastic designs.
• Designed tooling, fixtures, and jigs to support prototyping and production processes for machine sub-assemblies.
• Updated and maintained routing and wiring layouts using AutoCAD in compliance with technical and industry standards.

Senior Design and Development Engineer - Motherson Technology Services - Coimbatore, India

(2022-05 - 2025-04)

• Conceptualized and developed a Flexible Thermal Unit (FTU) for electric vehicles using hybrid circuit technology, ensuring lightweight, reusability, and manufacturability, aligned with OEM thermal requirement teams.
• Supported battery electric vehicle (BEV) coolant system development, including manifold design for efficient coolant routing to radiators, powertrains, and electronic components.
• Designed optimal coolant flow paths with minimal pressure drop, integrating CFD and FEA feedback through a simultaneous engineering approach.
• Created detailed 3D part and assembly models, 2D manufacturing drawings, and RFQ packages in compliance with ASME Y14.5 and ISO GPS standards; managed BOM creation and updates in SAP for Sample A, B, and C stages.
• Performed tolerance stack-up and fit analysis, coordinated with OEM clients on mounting fixation and tooling feasibility, collaborating with mold makers and simulation engineers.
• Managed cross-functional collaboration between the Indian offshore design team and German development team, ensuring seamless cross-regional project execution.
• Led the full project lifecycle from design to validation for major automotive OEMs, including BMW, Volkswagen, and Mercedes-Benz.

Design Engineer R&D Department - Neotech Medical System Pvt Ltd. - Chennai, India

(2020-10 - 2022-03)

• Experienced in designing medical machines using UG NX CAD, SolidWorks, and AutoCAD, including material selection, creating new design concepts, and proposing improvements to clients.
• Skilled in preparing detailed assembly and component drawings for production and suppliers.
• Proficient in updating design processes and BOM in SAP, conducting design validations based on customer requirements, and following up on prototype performance to resolve issues and implement improvements.

Junior Engineer NPD - Metexim sourcing pvt ltd - Chennai, India

(2017-09 - 2020-09)

• Involved in end-to-end New product development (NPD) from concept to production release.
• Created 3D models and 2D drawings for product assemblies and components.
• Developed and optimized designs for Transmission gears, valves, and steering housings.
• Modified existing designs to improve performance and manufacturability.
• Applied GD&T and tolerance analysis for fitment validation.
• Experienced in APQP, PPAP, and DFMEA processes and documentation.

BE/B.Tech/BS - Mechanical Engineering - Anna University (2013 - 2017)

Diploma - Design and Development & Problem Solving - CADD Centre (2017-01 - 2017-12)