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Mechanical Engineer

West Bloomfield Township, Michigan, United States
April 21, 2017

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Sunil Nalla

**** * ********* • Westland Michigan-48185 • 816-***-**** •


Experienced Design Engineer with a hands-on approach in tackling projects, product improvements, and to support prototype and production build activities.

Technical Skills:

CAD Tools: CATIA V5r21, Solidworks, NX Unigraphics 9.0, ANSYS, AutoCAD, Pro-E/CREO

Tools: Microsoft excel, Microsoft office, GD&T


Master of Science in Mechanical Engineering (GPA: 3.57/4) Graduate July 2016

Lawrence Technological University, Southfield, MI

Bachelor of Science in Mechanical Engineering (GPA: 3.12/4) Graduate May 2013

Jawaharlal Nehru Technological University Hyderabad, India

Professional Experience:

CAD Design Engineer May 2016 - Present

TSS Inc. Warren, MI

Develop CAD models of complex components and assemblies and revise existing CAD drawings using CATIA/solidworks also creating complex layouts using Pro-E/CREO

Generating detailed drafting and BOM’s for filing patent application of new products.

Responsible for Reading and interpreting blueprints, technical drawings including GD&T.

Communicate information to and from internal and external organizations for product improvements, and to support prototype and production build activities.

3D visualization and prototyping of new projects for prospective customers and 3D printing prototype for testing purpose.

Assistant Engineer- Dept. Quality Assurance June 2013 - Nov 2014

United Seamless Tubulaar Pvt. Ltd., Hyderabad, India

Performed physical tests which includes tensile, yield, hardness and impact testing.

Visual inspection, Hydrostatic test, drift and end area inspection.

Conducted Non-Destructive Testing (NDT) using Ultrasonic and Eddy.

Professional Affiliations:

SAE Team Member – Body/Chassis Design Lead, June 2015 – July 2016

Blue Devil Motorsports, LTU Southfield, MI Chassis Team Member Blue Devil Motorsports:

Designed and performed FEA for chassis and suspension to optimize it for possible static and dynamic loads.

Designed engine and muffler mountings collaborating with Powertrain Team.

Designed and fabricated brake mountings for brake calipers. Also, calculated the theoretical stopping distance and time to stop the vehicle as per the specs.

Assist teammate to incorporate steering mechanism and participated in the research work of steering system to gain balance with the handling.

Developed and followed inspection procedures and best methods for performing inspection using GD&T.

Design Specialist, Design of Chassis for Assembly/Manufacturability:

Responsible for achieving higher manufacturability and reliability, using detailed design in FEA and CAD.

Assisted drafters in developing the structural design of products using CAD software and saved 15% of the material and the overall weight for chassis.

Created team flow charts include technical processed and project timing. Wrote Tech/Cost report include program plan, technical matters relating, cost estimation, and control.

Tested the feasibility, design, operation and performance of equipment, components and systems.

Relevant Experiences:

Engineering Intern Nov 2012 – May 2013

AithCrew Engineering Solution Pvt. Ltd, Hyderabad, India

Performed Design considerations analysis and assisted senior Design Engineers in Designing of Head Lamp Cover using Catia V5 R21

Assisted senior Engineers in DFMEA analysis to check for any potential failures.

Performed FEA analysis such as stress analysis and vibrational analysis using ANSYS software for possible static and dynamic loads.

Engineering Intern Dec 2011 – Sept. 2012

Dura Automotive Hyderabad, India

Working on a variety of engineering tasks such as test planning, instructions, review and reports, project layout, design, develop, and implement new test procedures, perform complex test data analysis utilizing statistical methods, and maintain, troubleshoot and coordinate repair of mechanical test equipment.

Participating in corrective action, problem solving, and continuous improvement activities.

Interface with Senior CAE Engineer and Supervisors on updates/new test procedures, equipment, and methods.

Working with existing test system software to develop test processes and programs to satisfy DV testing needs.

Engineering Apprenticeship April 2011 – Oct. 2011

Hyundai Motors Ltd Hyderabad, India

Executed measure phase in DMAIC process to decrease lead time, defects, and deviation under the guidance of senior engineer

Assisted in performing Root cause analysis and DFMEA to determine failure in automotive components.

Performed testing by supervising bending, tension and fatigue tests and reported to quality manager.


Aerodynamic Performance Assessment of a car, Lawrence Technological University, Southfield, MI

Performed Computational Fluid Dynamics analysis of a car model at different angles of attacks, where the mesh is morphed to change back rake angle and improve fuel efficiency.

Fuel Economy Analysis Project

Determined real time fuel economy by varying parameters such as Final Drive, Transmission, Drivetrain layout, and Simulations were carried out on different transmissions like regular TC, CVT and DCT and results are compared.

Brake Drum Crack - Problem Solving

Main objective of the project was to find possible solutions to overcome the cracking due to stresses developed on the surface of the drum. Implemented concepts of 8-D, FMEA and 5-Box Durability Method to identify the root cause and solve the problem.

Development of FRP leaf spring, Central Institute of Plastics Engineering and Technology, Hyderabad, India

The project involved in the development of fibre reinforced plastics for the replacement of current steel springs for a commercial 4- wheeler. The ultimate goal was to reduce the weight of the springs thereby reducing the weight of the vehicle.

Parking Brake, DURA Automotive Systems, Pune, India

This project involved parking brake Design and Development process including its working mechanism, principle, brake ratio calculations and also manufacturing and assembly of such a brake.

Honours and Awards:

SAE Super mileage car achieved fuel consumption rate of 319 MPG placing 20th position at Shell Eco-Marathon 2016, COBO Center MI

Scored 365points for our vehicle design, ranked 4th position at SAE Supermileage 2016, Marshall MI

Finished 13th and clamed ‘Best New Comer Performance’ award at SAE Supermileage 2015, Marshall, MI

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