Mechanica Engineer

Anil Pratap Singh

Mob: +1-510-***-****

Email: *************@*****.***

Address: **** ******* **, *** ****** MD 21774

Summary

A dynamic professional with 20 years of experience in communication, aerospace, industrial, and automotive products, including 12 years of specialized expertise in new product design and development for electronic packaging such as phased array antennas, Polarizer, Radome design and sensors. Skilled in project management, planning, and cross- functional collaboration to deliver innovative, high-quality solutions.

• Exceptional problem solving and sound decision-making capabilities, coupled with excellent communication and interpersonal skills.

• Closely working with upper management and customer for the new requirements, sustaining projects, project budget, timeline update.

• Having good experience as Hybrid role as mechanical engineer with Mechanical Lab Manager.

• Current project -One Web Phase Array Flat Panel Antenna (HDX/FDX – Fixed, land mobile and Train concept): Antenna concept design, lead all part design and drawing such as metal enclosure, polarizer, Radome design, polarizer artwork outline, CCM, RCM, BFA board outline structural analysis, thermal analysis, of the self-part selection, prototype, tooling supplier coordination, FAI parts TMSA release, BOM, Hydrophobic coating research, selection for radome and rain testing, solar radiation, UV testing, HVT plan and HVT testing as per the customer requirement, Report making submit to customer with CFT team, production support and resolve assembly issues.

• Hands on all mechanical system such as structure, enclosure, bus bars, PCB board, I/O card, display, battery mounting in high and low voltage environment.

• Having 3D modeling and 2D drawing experience in injection molding plastic, sheet metal and casting parts with small and large assemblies.

• Experience for product testing as per UL certification, IP6X rating – dust testing, drop testing, waterproof testing as needed, humidity, UV ray’s exposure, EMC/EMI testing, PD test and prepare test plan with the testing team.

• Having experience on structural, vibration and thermal analysis and good practice to design for manufacturing.

• Responsible for Lithium-ion battery packaging and mounting brackets design and battery testing equipment concept design support for electrical motorcycle.

• Working with cross functional team for the product manufacturing process, project plan, risk mitigation, tooling validation, timeline, Gantt chart, resource utilization.

• Extensive experience in gathering requirements, work estimation, schedule monitoring and tracking, controlling changes & managing delivery to customer.

• Having experience to work with cross functional team for project from prototype to production release.

• Experience in design of light weight plastic parts & electronics enclosures, pcb board covers, fender, & hood such as material polycarbonate, fiber glass, ABS-PC & plastic proto materials.

• Having experience in concept design and validation and verification.

• Having experience for design review and CTF dimension, DFM, DFA and tolerance stack up analysis and ASME 14.5 GD&T.

• Hands on all type of material selection based on product requirement.

• Having good experience in prototype with 3D printer and proto validation.

• Having experience in product NPD process from concept to production.

• Having experience of DVP, APQP, PPAP, PFMEA, DFMEA & Control Plan documentation.

• Having experience in manufacturing process such as injection molding, stamping, LPDC, GDC, sand mold casting and machining.

• Having experience to coordination with worldwide vendors and customers.

• Having third-party resources, component supplier/vendors and manufacturing vendors.

• Having experience to work with third part contractors, onsite offshore coordination on regular basis.

• Proficient in managing entire spectrum of Product Development activities, which include feasibility study, design, selection, vendor discussion, process set up for production in terms of assembly.

• Flexible for long sitting, factory walk working culture and work in pressure. EDUCATION

M.Tech: Mechanical Engineering (Production) Sept 2010- June 2012 Singhania University of Rajasthan, India

B. Tech: Mechanical Engineering July 2001 – June 2005 Dr.B. R Ambedkar University of Agra, India

IT SKILLS

• CAD Tools: Pore/Creo, SolidWorks, Unigraphics, AutoCAD, Flow EFD, Flow therm, Creo simulation Live

• PLM- Windchill, SAP, Agile.

• Management: Smart sheet, Power Point, Excel, MS Project, word. PROFESSIONAL EXPERIENCE

Principal Mechanical Engineer (R&D) Oct 2021 to till date Hughes Network System, Germantown, MD

• Mechanical design lead for LEO Phase array flat panel Antenna (Half and full duplex) as Fixed and land mobile.

• Managing team (4 engineers), Team budget, project budget planning, task assigning, design update.

• Regular internal and vendor meetings, action item sheet with CFT members for completed & next action items until task closed.

• Working on hybrid role as mechanical engineer with Mechanical Lab Manager-Responsible for 3D printing of plastic prototype, Lab tool maintenance and calibration, tools Inventory, every year new tools/testing equipment based on project requirement budget proposal and buying with installation in the lab. Prepare guideline and helping junior engineers to product testing in lab, making proto assembly and testing such as thermal chamber

(Walkin/mid-size), Solar radiation (UV chamber).

• New project Concept design as per the customer requirement and submit as proposal for the approval.

• 3D and 2D for Aluminum and plastic enclosure (Casting design), Polarizer and Radome material selection and design, BOM preparation, Assembly structure, CCM board, RCM board, BFA board outline and mechanical cad design, Custom cable drawings, thermal shield design, OTS part selection such as board connector, GPS antenna, power and ethernet connectors and cables, Structural and thermal analysis.

• Radome (White color): Radome material selection (Sabic polycarbonate) and design, machined radome

(Bonded with polarizer) with injection molded bezel. New material research with similar Dk value @10GHz as machined material, one piece injection molded Radome design (Covestro Polycarbonate with and without glass filled material) which resolved the assembly time, UV stabilized (Prevent yellow color during solar radiation) with UV additives, reduction, outdoor stability, weight reduction, environmental sealing issue.

• Hydrophobic Coating: Research hydrophobic coating for the radome to prevent performance during rain. worked with supplier and create new ceramic/water-based material with better adhesion property and long-term solution min 5 year as company warranty required. Define coating process at factory and repair process with kit at field if required. coating test to prove Min 5-year pass: Malt Test (+55 C to -40 C with high an low rain speed), Solar radiation test based on ASTM G154 standard, dust test, Bird’s wate (poop) test.

• Responsible to complete product design-based on UL standard, Rohas and Reach.

• Responsible for Prototype making and testing before tooling start. Tooling suppler selection and send parts for tooling. DFM review, FAI part checking and TMSA release.

• Desing verification, HVT (Hardware verification test) test planning and execution as per the customer requirement including in survival and operational conditions such as temperature, cold start, Solar radiation, Humidity, weather resistance, sock and vibration resistance, wind test, Malt/ Halt test, packaging drop test.

• Responsible to support production team to resolve assembly issues at shop floor until production start.

• Desing leak tester and prepare leak testing process to make sure leak proof product (water sealed/dust proof).

• Responsible for the hydrophobic quoting selection in rain, dust, UV and atmospheric temperature conditions.

• Design for manufacturing (DFM) with GD&T as per ASME 14.5 and tolerance stack up analysis.

• Responsible for new ECN's, ECO's for new drawing release and ECN revision for new revisions.

• Closely working with production team, purchasing team, quality team.

• IT Software: Creo, Windchill, Flow EFD, Flow therm, Creo simulation Live, Solid works, Excel, word. Lead Mechanical Engineer (R&D) June 2018 to Oct 2021 GE Aviation, Dayton, Ohio, USA

• Mechanical design lead for aircraft AC/DC and DC/DC invertor/Convertor design.

• Regular internal and vendor meetings with follow-up and action item sheet with CFT members for completed & next action items until task closed.

• Closely working with upper management for design update, project plan and test planning.

• 3D and 2D for enclosure structure, sheet metal, bus bars, plastic parts, PCB boards (CCA), wire routing.

• Concept generation for CM/boost inductors design and verification with the help of electrical and electronic team.

• Responsible to complete product design-based EMI requirement, EMI gasket selection and EMI testing.

• Responsible for design (3D and 2D), encloser, busbars, cold plate, brackets and other hardware’s for assemblies.

• Responsible for product material selection such structure part material, hardware material, connectors based on product requirement within the aerospace standard and UL requirements.

• Responsible for regular engineering team meeting and maintain action item sheet in smart sheet.

• Responsible for assembly Bom, drawing tree maintain in smart sheet with all technical information (GE part numbers, COT part numbers, vendor information, QC check, part ordered, sample testing, analysis result).

• Design for manufacturing (DFM) with GD&T as per ASME 14.5 and tolerance stack up analysis.

• Responsible for 3D & 2D drawing review and other documents sign-off and release in windchill.

• Responsible for material selection such hardware and structure part material based on product requirement.

• Responsible for new ECN's, ECO's for new drawing release and ECN revision for new revisions.

• Creating top level and sub-assemblies as well as managing complete BOM in drawing and excel sheet.

• Responsible to coordination with FEA team for analysis such as structural, Vibration, thermal.

• Vender coordination for part manufacturing/development and off the self-items, prepare RFQ and submit to supplier team.

• Responsible for product testing and report making such as EMI testing, PD testing, thermal testing, humidity testing.

• Responsible design verification, validation, testing.

• Responsible for FAI (First article inspection) and report checking.

• Planning & co-ordination from onsite to offshore of day-to-day activities.

• Closely working with production team, purchasing team, quality team and supply chain team.

• IT Software: Creo, Windchill, Oracle, Excel, word. Mechanical engineer (R&D) Nov 2016 – May 2018

Georg Fischer Signet, Elmonte, CA, USA

• Responsible as mechanical engineer for chlorine analyzes, megameters, pH/ORP sensors, network box from 3d design to release.

• Concept design and 3D printing (Mechanical, electrical and electronics) – Flow sensors plastic parts design such as cover, mounting bracket, enclosures, PCB boards, connectors and many small parts as needed in product from concept to final parts with 2D drawings.

• Responsible for 3D cad models, 2D drawings, Bom table, Top and sub level assemblies in Unigraphics and data management in agile.

• Design for manufacturing with GD&T ASME 14.5 and tolerance analysis.

• Responsible for product testing in-house/outside as per UL certification, IP6X rating – dust testing, drop testing, waterproof testing as needed, humidity, UV ray’s exposure, EMI testing.

• Responsible for PR/TRD document, method sheets for machining, assembly processes.

• Hands on selection such as material, fasteners, connectors, adhesive double-sided tap, panel, surface finish, manufacturing process and product packaging selections as per product need based on UL requirement.

• Responsible for all document & drawing sign-off through CFT team (purchasing, warehouse, manufacturing, quality, industrial engineering, production team) as well as ensure production readiness.

• Responsible for vendor discussion and visit for all aspects such as tool design, sample parts, tool trial, packaging.

• Closely work with quality team to complete DFMEA, FMEA, control plan and sample parts dimensional reports.

• Checking & checkout the existing Part, drawing & Assy.

• Responsible to review tooling DFM and coordinate with vendor.

• Organize research and lead brainstorm events around unique customer problems.

• Create new ECN's, ECO's and make changes as needed with new revisions and update 2d drawing and 3D models as per ECN.

• Responsible to review first article inspection report as mechanical engineer and signoff document.

• Determine ideal component manufacturing route to ensure overall design, performance, and cost conformance.

• Interact with supplier team, quality team, manufacturing groups, outside vendors for all technical aspects.

• Continuous improvement, solving technical issues and drawing signoff with new revisions.

• Closely working with production team, purchasing team, quality team and supply chain team.

• Cad / PLM Software: Pro-E/Creo and Windchill.

Asst Manager Jul 2011 to Nov 2016

L&T Technology services, Vadodara, India

Automotive design support (ATV, Motorcycle,)

• Project managing & team handling of 5-6 team members such task assigning, project planning, report making with MS word, Excel & presentation on PowerPoint.

• Updating SharePoint for new & on-going task with respect to its billable hours & uploaded dates etc.

• Lead design reviews for technical readiness of projects & to ensure adequate input & involvement from all interested groups.

• Responsible for Lithium-ion battery packaging and mounting brackets design support for electrical motorcycle.

• Lithium-ion battery testing equipment concept design.

• Worked on GD&T, Tolerance Stack up Analysis.

• Develop 3D cad models & 2D drawings of components & sub-assemblies in Creo.

• Evaluate & create ECN/ECO requests & coordinate design changes requested by the customer/vendor.

• Design for front & rear Suspension, Chassis, frame, Wheels, Brakes Clutch, Front fork Vehicle Controls Design, Engine Intake & Exhaust system, ATV, & Motorcycles with solid works data management windchill

• Hands on ATV sheet design, door trim, A/B pillar hood, fender, & motorcycle saddle bag design for manufacturing.

• Provide technical assistance to customer’s/vendors & functional groups such as purchasing, test, vehicle validation, product engineering.

• Design of spacers, side stand bracket, Brake design for Motorcycle & ATV.

• Concept design of alloy wheel model & front Fork, Triple clamp for the motorcycle.

• Concept generation & communication of front & rear engine mounting brackets for various engines & for different off-road models.

• Updating SharePoint for new & on-going task with respect to its billable hours & uploaded dates etc.

• Taking care of SharePoint discrepancies if any with proper co-ordination with the offshore engineers.

• Planning & co-ordination from onsite to offshore of day-to-day activities.

• IT software: ProE/Creo, Windchill, excel, word.

Asst Manager Dec 2008 – July 2011

Rico Auto industries, Gurgaon, Haryana, India

• Worked on various projects related to Product design & development, complex part modeling, reverse engineering, sheet metal, surface modeling, large assembly modeling and drawing generation.

• Converted the 2D drafting of Fixtures of casting components to 3D modeling that included Master assembly development, making manufacturing drawings and BOM.

• Casting design for automotive components like Eaton front Case, Pipe angle, Pipe intake, Honda Alloy wheel

(Front Disk, Drum).

• Tooling design for Aluminum (LPDC and GDC), ferrous material (sand mold casting).

• Responsible for deciding parting line and core box designing.

• Flow simulations on Magma Software to eliminate the defects including, porosity, shrinkage, surface defects.

• Detailing of various components & BOM generation.

• APQP, PPAP, PFMEA documentation

• 3D Cad and 2D drawing in Unigraphics NX6, Pro-E. Design Engineer Aug 2005 - Dec 2008

Continental engines Ltd. Bhawadi, Rajasthan, India

• Design for automotive components like Tata 2 Cyl head, Nissan Cylinder head, Eaton rear Case, Lombardino 3cyl head, brackets, plastic parts.

• Feasibility of new component development.

• Tooling design for Low Pressure Die Casting, Gravity dies casting.

• Responsible for deciding parting line and die design and core box designing.

• Detailing of various components & BOM generation.

• APQP, PPAP, PFMEA, DFMEA and Control Plan documentation.

• Read drawings, utilizing General Dimensioning and Tolerance.

• Travel to suppliers to perform audits follows up on corrective actions, perform Level PPAP, or conduct APQP.

• 3D cad and drawing in Unigraphics and Pro-E.

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