• Responsible for mixed material mechanical joining and body fastening (Projection welded, drawn arc welded, clinch and pierce fasteners etc.) for upcoming and existing Models at Tesla.

• Led the Mechanical joining (SPR and Rivtack) and Body Fastening (Projection welded, drawn arc welded, clinch and pierce fasteners etc.) project of Model III. This included joint design, joint development, equipment identification, equipment procurement (102 EOAT worth USD 9M), equipment installation, equipment commissioning, joint validation and handover. Managed 5 suppliers from beginning till end.• Led the validation of all Model X castings during transition from supplier to in-house builds. This included joint validation, dimensional validation, crash tests and repeatability validation.• Worked on feasibility of commonizing mechanical joining of Model S on Model X line.• Designed, Validated, launched SPR, Rivtack, Flow Drill Screws and Drawn Arc Stud joining for Model X program. This includes every single task for R&D, all prototype builds and production line setup until handover of Program to Production.• Worked on Design feasibility and Production trials of Magnetic Pulse Welding, Resistant Element Welding, and Friction Bit Joining for mixed material joining.• Drafted and Released Tesla SPR specification and Rivtack specification.• Established Tesla Joint Teardown shop, fully capable of tearing down BIW into discrete joint elements. Lab is equipped with Plasma cutting, heavy duty chisels, all grinding, cutting, sanding, drilling and milling equipment for aluminum and HSS.• Established a Joint Testing Lab at Tesla that is fully capable of micro-sectioning, hardness testing, thermal-corrosion testing, all types of tensile testing along with joint related NDT tools and fixtures.

Working on CKD Programs (International Jeep Programs) and Aluminum sheetmetal joiningLaunched 2015 Jeep Wrangler and 2015 Jeep Grand Cherokee in Cairo, Egypt. Implemented low cost quality improvement processes for water test booth, process and repair and effective way of destructive/nondestructive weld inspection.

Responsible for designing, implementing and validating all aluminum fastening joints (Self-pierced nuts, self-pierced studs/bolts, clinch nuts/bolts/studs, insert nuts/studs, flow drill holes, extruded blocks and drawn arc weld applications). This task also included completing fastener feasibility, writing repair specifications and developing non-destructive testing specifications.Leading evaluation of future joining technologies (friction spot welding, lock bolts etc.) for possibleforward model implementation.Introducing, validating and implementing cost reduction ideas on all types of joining by benchmarking, evaluating different supplier’s fasteners, modifying design and reducing the number of joints where possible by making sure the joint has same integrity.Support design and release of structural joining (self-pierced rivets, clinches and flow drill screws) for application engineers. Involved in development of MDS of structural joining technologies and writing deviations from manufacturing standards.Single point of contact for fastening issues on the P552 VP builds. Led the engineering and supplierteams in issue resolution and developed Lessons Learned to avoid these issues in the future.  Working on galvanic corrosion protection and surface treatment specification/repairs.  Team member for PFMEA of Aluminum Resistance Spot Welding.Developed and implemented P415 SPR Pullahead Program (self-pierced rivets, clinches and flow drillscrews).Worked on determination of actual thinning percentage of aluminum panel after stamping and trimming to final product.

Designed automated laser cutting machine parts using Solidworks 2010.Used Solidworks for designing structural members, machinery components, and sheet metalguarding right from the concept.Responsible for material selection, modeling, (analysis where required), and packaging.Drafted from scratch which included detailed drawings, GD&T, annotation, and tables (BOM etc.).Coordinated with suppliers by visiting their facilities and working out cost reduction measures andfeasibility to manufacture.Fabricated and assembled mechanical and electronic components of machinery.Other duties included purchasing products, some hands on (drilling, milling, lathe, cutting, weldingand assembling) and simulating overall machinery on CAD (Solidworks).

Designed, analyzed, fabricated and tested a three wheeler powered by rotary compressed air engineusing SOLIDWORKS 2008 as a design software.Major of the design includes, by wire technology to control acceleration, brakes and steering of vehicle, a unique rotary compressed air engine fabricated using aluminum, body using fiber reinforced plastic and chassis using aluminum.