Aspiring EV Mechanical Engineer with 4+ Years Experience
Resume:
KHAIRNAR TEJAS P.
MECHANICAL ENGINEER
*****************@********.**
Pune, India
Profile
Enthusiastic and results-driven engineering professional with 4+ years of technical experience in Electric Vehicle
(EV) product design and development. Demonstrates strong teamwork, leadership, and project planning abilities, with a proven track record of managing multiple high-impact projects in fast-paced, dynamic environments. Highly adaptable and solutions-oriented, with a focus on delivering practical, innovative engineering outcomes. B.E. Mechanical Engineering 2019-2023
Pimpri Chinchwad College of Engineering, Pune.
HSC 2017-2019
HPT arts and RYK science college, Nashik.
SSC 2016-2017
Kil Bil English Medium School, Satana, Nashik.
Process Engineer - Exponent Energy PVT. LTD. 12/2023 - 03/2025 Conducted Design for Assembly (DFA) sessions with cross-functional teams (CFTs), delivering actionable inputs to improve assembly efficiency.
Led New Product Development (NPD) initiatives, including planning and execution of prototype builds and transition to mass production.
Prepared and reviewed PFMEA documents with CFTs; derived critical process parameters and IPQC checkpoints based on RPN analysis.
Created comprehensive SOPs and Process Flow Diagrams (PFDs) to ensure seamless production readiness and operator clarity.
Designed custom assembly fixtures in SolidWorks, including 3D modelling, load calculations, and structural FEA simulations for strength validation. Generated 2D manufacturing drawings with GD&T and performed tolerance stack-up analysis to ensure fixture accuracy for CTQ parameters.
Conducted Design of Experiments (DoE) to address production bugs, resulting in a 19% reduction in takt time through process optimization.
Performed Root Cause Analysis (RCA) on production issues using data collected via 8D methodology, driving continuous improvement.
Utilized Siemens Teamcenter (PLM) to manage project data, track revisions, and release parts and technical documentation.
Education
Professional Experience
Product Developement Engineer - Replus Engitech PVT. LTD., Pune 07/2025 - Present Responsible for end-to-end mechanical design of Power Distribution Units (PDUs), including 3D modeling, electronics packaging, thermal management, and compliance with UPS system requirements. Implemented GD&T standards in the design of sheet metal enclosures to improve dimensional accuracy, reduce assembly issues, and enhance product quality. Used Creo for sheet metal design, applying DFM principles to ensure precision and manufacturability. Mechanical Design Engineer - XDM Printing Solutions LLP. 01/2023 - 06/2023 Acquired in-depth knowledge of Additive Manufacturing and Rapid Prototyping techniques, including FDM, SLA, SLS, and Vacuum Casting.
Designed and developed India’s first 1m x 1m FDM 3D printer, enabling large-scale rapid prototyping capabilities.
Engineered enhancements that increased printer stability, achieving 5 faster printing speeds without compromising output quality.
Projects
Mechanical Design Engineer - Team Kratos Racing Electric. 07/2020-08/2023 Design and Development of an FSEV.
Led a team of 4 undergraduate members through the complete development cycle of a Formula Student Electric Vehicle (FSEV) transmission system, from concept to prototype. Calculated and finalized the Final Drive Ratio using hand calculations and point mass simulations, validated results through experimental testing.
Designed and analysed transmission components including shafts, customized limited slip differential, and bearing selection based on detailed load calculations. Developed a single-stage reduction gearbox and customised convertible Limited Slip Differential tailored for FSEV high performance requirements.
Performed structural simulations (FEA) using ANSYS Workbench and 3DExperience, including high- quality mesh generation and refinement for accurate FEA results. Created 3D CAD models in CATIA V5 and 3DExperience; ensured manufacturability and design accuracy. Prepared detailed 2D manufacturing drawings with application of Geometric Dimensioning and Tolerancing
(GD&T) for production readiness.
Implemented Design for Assembly (DFA) principles, achieving an 80% reduction in assembly time of the system.
Technical Skills
Catia V5
Siemens Teamcenter
Creo Parametric
DFA
Solidworks
3DExperience Enovia
MS Office
DFM
3DExperience
Autocad
Ansys Workbench
FMEA
Awards and Achievements
Participated in International Design Competition Formula Student East & Formula Student Germany. 3DEXPERIENCE Student Champion.
AIR 1 in Formula Bharat Event.
University Level Kabaddi Competition
Declaration
I hereby declare that the information stated above is true to best of my knowledge and belief. I take the responsibility of any mistakes in data if occurs in future. Tejas Khairnar
Evaluated and selected the most effective leak testing method, improving testing accuracy and repeatability by 18%.
Commissioned and proved out an automated adhesive dispensing machine, ensuring integration into production line with minimal downtime.
Applied Cp, Cpk, and GRR analyses for validation of critical processes and equipment capability.
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