SARANG BIRWADKAR

Dearborn, MI ***** (open to relocate) 313-***-**** ad1iw1@r.postjobfree.com LinkedIn Portfolio EDUCATION

Master of Science in Engineering in Automotive and Mobility Systems Engineering Exp. Grad.: Apr 2025 University of Michigan, Dearborn, MI, USA

(Courses: Vehicle Ergonomics, Automobile - An Integrated System, Composite Materials) Bachelor of Technology in Mechanical Engineering Graduated: Jul 2022 Sardar Patel College of Engineering (University of Mumbai), Mumbai, IN GPA: 3.53/4.00

(Courses: CAD / CAM / CIM, Engineering Drawing, Design of Machines & Mechanical Systems, Finite Element Analysis) TECHNICAL SKILLS (PORTFOLIO)

• Design (CAD): CATIA V5 SOLIDWORKS AutoCAD Keyshot

(GD&T, Sheet Metal Design, 3D Forms & Shapes, Wireframe & Surface Design, Machine Design and Vehicle System assemblies, 2D Engineering Drawing, 3D CAD Modelling & Rendering)

• Simulation & Analysis: ANSYS Workbench ANSYS PRE-ACP STAR CCM+ MATLAB Simscale

(FEA (Static Structural, Dynamic & Composites), CFD, Topology Optimization)

• Mechanical: CAE / CAM DFMEA Machining / Fabrication / Prototyping Product Design and Rendering RELEVANT EXPERIENCE

Mechanical Battery Pack Design Engineer Coulomb LiTech Pvt. Ltd. Mumbai, India Feb 2023 – Jul 2023

• Delivered 22 distinct compact battery packs across a range of voltage, from LV 12V lead-acid battery replacements, to 24V, 48V, 51V, & 72V HV battery packs for Electric Vehicles (EVs) such as forklifts, shuttles, club cars, & more.

• Implemented sheet metal design to create detailed 3D CAD models of enclosures for packaging prismatic & cylindrical cells, while focusing on ease of maintenance, manufacturability, cost & compliance with AIS-156 safety standards.

• Demonstrated strong technical problem-solving skills by effectively liaising with vendors, integrating design revision- based feedbacks to attain unprecedented compactness in battery packs just within week-long deadlines.

• Effectively showcased high-quality digital prototypes of 3D models & their animations to clients & stakeholders for marketing purposes utilizing advanced rendering techniques using Keyshot software & brochures made with CANVA. Formula Student Race Car (FSAE Motorsports Team Project) SPCE Racing SPCE, Mumbai Oct 2018 – July 2022

• Collaborated in cross-functional team with over 45 engineers across 8 departments while taking charge as the Head of the Aerodynamics department.

• Managed all the phases of the design process, provided design direction on components, assemblies, GD&T and documention as a mentor.

• Designed undertray, diffuser, 3-element wings, under-body, bluff body for the FS Vehicle, and collaboratively designed knuckle (upright), steering system assembly for go-kart using CATIA V5 employing surface modelling & shape design.

• Achieved 31% reduction in drag coefficient (Cd) of vehicle body compared to the previous vehicle by performing iterative CFD analysis on STAR CCM+, reducing 1.5 seconds per lap on Optimum Lap.

• Cut down manufacturing costs by 70% by manufacturing molds for all the composite body panels in-house from XPS foam employing hot-wire cutting and compression moulding techniques.

• Manufactured body panels, ergonomic seat, dashboard and steering wheel, in-house using CFRP & GFRP fibre/epoxy composites employing wet-layup techniques reducing weight by over 20%. RELEVANT PROJECTS

Design & Optimization of Wheel Rims with Chopped Carbon Fibre Reinforced Epoxy Composite Sep 2021 – Sep 2022

• Designed carbon fiber wheel rims on CATIA V5 and utilized ANSYS’s topology optimization tool to achieve significant reduction of 35% in unsprung mass of vehicle, maintaining FOS of over 4.

• Conducted thorough testing of CCF reinforced epoxy composites on UTM using ASTM-standard flexural, tensile, & compressive tests, with varying fibre volume ratios to conclude the optimal ratio of 40%.

• Employed ANSYS CAE tools to incorporate material data obtained from these tests for the designated Fiber Volume fraction (FVF) into dynamic FEA simulations.

• Evaluated both static and dynamic structural FEA of rim in multiple scenarios viz. bumps, turns, and braking during turns.

• Secured the Best Presentation award for the research at RDME National Conference hosted by AIP Publishing. Designing of a Two-stage Reverted Helical Gearbox Sep 2021 – Sep 2022

• Designed a 3D-CAD and evaluated the adequacy of a custom-built two-stage reverted helical gearbox to fulfil desired specifications, satisfy failure criteria and provided a detailed calculation report.

• Adeptly factored in considerations to design the mechanical system to meet real-life needs, including estimated gear- life and bearing life calculations, shaft tolerances, lubrication, operating temperatures, manufacturability, sustainability, economics, packaging, ergonomics, safety, and aesthetics.

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