• Engineered and optimized modular mounting systems and accessories using SolidWorks, ensuring structural integrity and thermal performance of lithium-ion batteries in Battery Energy Storage Systems (BESS).• Conducted in-depth structural FEA, thermal FEA, and CFD analyses to establish and validate design parameters, optimizing system reliability and thermal management under dynamic operational conditions.• Generated precise technical drawings and manufacturing documentation, enabling seamless fabrication and integration of components in compliance with rigorous industry standards.• Collaborated on AI-driven thermal management and energy optimization strategies, enhancing battery lifecycle efficiency and supporting the development of sustainable second-life battery applications.

• Developed process flow charts using Microsoft Visio to analyze the battery manufacturing line in the Burlingame facility, utilizing process engineering methodologies.• Collaborated with the different engineering teams to create and maintain PFMEA (Process Failure Modes and Effects Analysis) documents, ensuring product quality and reliability.• Drafted and updated production work instructions and managed work orders with Nomuda Visual Factory, adhering to standard operating procedures (SOPs) and ISO 9001 quality standards.• Created and refined production line layouts with AutoCAD, employing lean manufacturing concepts such as 5S, Kanban, and value stream mapping to identify production inefficiencies and improve manufacturing KPIs (Key Performance Indicators).• Determined the flaws in fixtures by performing tolerance analysis and worked on re-designing/testing new fixtures, utilizing CAD/CAM software and statistical process control (SPC) techniques.• Coordinated with the Design, Advanced Manufacturing Engineering (AME), and Quality teams to determine and escalate potential remanufacturing challenges by implementing Design for Manufacturability (DFM), Design for Assembly (DFA), and Design for Serviceability (DFS) principles, ensuring product sustainability and cost-effectiveness.• Reviewed machine engineering drawings/BOMs (Bill of Materials) using 3DX Catia and communicated with vendors to obtain quotes for over $50k in critical spare/wear parts, resulting in a 35% reduction in downtime, leveraging supply chain management principles.• Researched the rework process of battery packs to minimize the scrap cost by 16%, utilizing root cause analysis (RCA) and failure mode and effects analysis (FMEA) techniques.• Performed Cycle time studies for line balancing and identifying the bottlenecks in the manufacturing process, utilizing continuous improvement methodologies of Six Sigma.

• Assisting Dr. Ken Youssefi in tutoring course “Design & Graphics” using SOLIDWORKS.• Evaluating assignments and exams for a batch of 30 students.• Conducting help sessions for the students weekly for doubt clearing

Research Assistant • Researched autonomous vehicle accidents patterns and made collision reports database for 2019-2021.• Designing structural safety guidelines for autonomous vehicles by performing the different crash tests in Ansys and SOLIDWORKS.