Aakash Kumar
Lead Chassis Engineer - Brakes at Fisker Inc
Lead Chassis Engineer - Brakes at Fisker Inc
•	Designed & released brake system components at EV start-up, Canoo.
•	Led a team of 25 engineers in the development of a prototype All-Terrain Vehicle (ATV).
•	Adept at performing DFMEA, Root Cause Analysis, Benchmarking and DVP&R for automotive systems. 
•	Designed chassis, exhaust and brake system components using CATIA and UG/NX.
•	2 years’ experience in Lean Product Development and managing suppliers.
•	Certified professional in product design and analysis by CADD Centre. 
•	Trained to optimize production process at Ford Motor Company.
Fisker Inc
https://www.linkedin.com/company/fiskerinc
Manhattan Beach, California, United States
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Lead Chassis Engineer - Brakes
Canoo
https://www.linkedin.com/company/canoo
•	Overseeing all of brakes for Canoo vehicles. Responsible for brake system design & release, supplier selection, budget projection, resource planning and supply base management with a team of engineers. 
•	Started from design release in May of 2019, now have production representative brake system on Beta Cars.
•	Coordinated brake system integration during first prototype vehicle build.
•	Identified the root causes of build issues and implemented corrective actions.
•	Designed cost-effective brake Evac and fill equipment for prototype vehicle.
•	Led design changes to meet system requirements, supplier tooling requirements and industry standards.
•	Created, routed, and maintained brake line assemblies in vehicle environment.
•	Worked closely with cross-functional groups to ensure brake line routings met packaging requirements and had mounting provisions in vehicle environment.
•	Seven suppliers have been sourced through production, and the commodities include primary and secondary brake control module, disc brakes, electric park brakes, rotors, dust shield, wheel speed sensor, brake pedal and master cylinder, brake lines and jounce hoses, brackets and fasteners.
•	Managed suppliers for delivery of parts and proper execution of design validation, process validation, and DFMEA.
•	Led PDT meetings with suppliers to ensure critical program milestones including design reviews and MRD dates are met.
•	Generated RFQ packages for sourcing new brake line assemblies to Tier 1 suppliers.
•	Conducted jounce hoses & wheel speed sensors articulation test at proving ground.
•	Designed & 3D printed brake line brackets and performed 3D scan to support wheel corner articulation test.
•	Created assembly instructions for all brake system components.
•	Created and maintained inventory of brake system parts for prototype build.
•	Assisted Chassis Program Manager in BOM (Bill of Materials) validation using DBeaver – database tool.
Torrance, California
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Chassis Engineer
University of Michigan College of Engineering
https://www.linkedin.com/company/university-of-michigan-college-of-engineering
•	Graduate teaching assistant for Automotive Powertrains, a graduate level course at the University of Michigan Dearborn.  
•	Participated in the assessment process using a variety of methods and techniques and provided timely, effective and appropriate feedback to 35 students to support their learning.
Dearborn, Michigan
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Graduate Teaching Assistant
University of Michigan - Rackham Graduate School
https://www.linkedin.com/company/university-of-michigan---rackham-graduate-school
•	Repackaged the engine oil sump (dry sump lubrication) to ergonomically optimize the driver seating.
•	Designed the oil catch cans for the FSAE vehicle using SolidWorks.
•	Redesigned the Engine Dyno cart to pass the university’s safety standards.
•	Liaised with the business team to assist in the make-or-buy decision making process.
Dearborn
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Powertrain Engineer - Formula SAE Team (FSAE)
Ford Motor Company
https://www.linkedin.com/company/ford-motor-company
•	Formulated strategy to increase the average die turnout to improve the die readiness in stamping department.
•	Performed time study analysis to identify the root causes of delay during die maintenance.
•	Conducted Process and Design FMEA on stamping department dies.
•	Participated in DRBTR’s and Root Cause Analysis (RCA) activities during vehicle launch environment.
Chennai, India
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Engineering Intern
SAE BAJA - Sairam Institute
•	Led a team of 25 engineers in the development of an All-Terrain Vehicle (ATV) based on SAE standards.
•	Designed vehicle space frame chassis and body using CATIA & UG/NX by collecting the necessary anthropometric dimensions of the ATV driver.
•	Designed lightweight and efficient drivetrain for the ATV by collaborating with the powertrain team.
•	Designed and developed brake disc and brake pedal assembly along with brake biasing using balance bar.
•	Performed Design Failure Modes Effects Analysis (DFMEA) to analyze design and mitigate risk.
•	Performed vehicle level testing on test tracks and collected data to develop countermeasures.
•	Liaised with the business team to assist in marketing and make-or-buy decision making process.
•	Managed suppliers and optimized parameters like cost, delivery and quality of the purchased components.
•	Organized weekly meeting with the project sponsor and coordinator to communicate the project status updates.
Chennai, India
Product Engineer
Master of Science - MS
Automotive Systems Engineering 
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University of Michigan-Dearborn
https://www.linkedin.com/school/university-of-michigan-dearborn/
Bachelor of Engineering - BE
Mechanical Engineering
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Anna University
https://www.linkedin.com/school/anna-university/
Society of Automotive Engineers (SAE) International
Student Associate
Indian Graduate Students Association (IGSA)
Member
Society of Automotive Engineers, India (SAEINDIA)
Associate Member
Indian Society for Technical Education (ISTE)
Student Member
Univeristy of Michigan - Dearborn
Non-Resident Graduate Student Scholarship
University of Michigan - Dearborn
Non Resident Graduate Student Scholarship
University of Michigan - Dearborn
Non-Resident Graduate Student Scholarship
University of Michigan-Dearborn
Non-Resident Graduate Student Scholarship
• Founded the club and recruited the Office bearers to frame the Constitution of the club.
• Launched the first Baja and Supra teams and encouraged continuous participation of all members in club
activities.
• Organized Tier 1 level SAEINDIA Student Convention 2016.
SAEINDIA Collegiate Club of Sri Sai Ram Institute of Technology
Chairperson
Advanced IC Engines
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Design of Machine Elements
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Design of Transmission Systems
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Engineering Thermodynamics
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Finite Element Analysis
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Fluid Mechanics and Machinery
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Vehicle Dynamics
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Auto Senors and Actuators
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Automobile - An Integrated System
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Automotive Manufacturing Processes
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Automotive Powertrain Systems
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Design of Automotive Chassis
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Electrical Aspects of Hybrid Electric Vehicles
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Engine Emissions
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Internal Combustion Engines
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Powertrain NVH
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Vehicle Electronics
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•	Performed modal analysis using Ansys Workbench on the aftermarket rear spoiler used in a passenger car and suggested an alternate design to improve its vibration properties.
•	The alternate design in which mass was reduced through thickness reduction and stiffness was increased through length reduction, had vibration frequency much greater than that of the vehicle body on normal roads (60-70Hz).
Modal Analysis of Spoiler in Passenger Car – NVH Optimization
Overview of my research work:

•  Proposed Machinable Austempered Ductile Iron (MADI) as the most suitable material for casting crankshaft in high performance engines.
•  Based on the investigation, concluded that MADI is a better alternative for forged steel crankshaft due to its high strength – weight ratio, high fatigue strength and comparatively lower cost.

Conclusion from comparative analysis: MADI vs Forged steel Crankshaft 

•   The manufacturing and processing cost of MADI is comparatively lower than hardened forged steel (up to 20%). Thus, MADI is an economical substitute.
•   Machining of MADI produces discontinuous chips which is easier to handle and recycle compared to continuous coil-type chips in steel machining.
•   MADI produces near net shape casting, so it requires very less machining compared to forged steel crankshaft.
•   MADI is 10% less dense than steel. So, effective weight saving can be achieved.
•   MADI has 40% higher yield strength, 25% higher tensile strength, 20% lower modulus and better wear resistance than forged steel.
•   Casting takes more production time than forging, so MADI cast crankshaft is suitable only for low production volume.
Analysis of Cast Iron Crankshaft in High Performance Engines
•	Developed series hybrid electric vehicle & battery electric vehicle fuel consumption simulator for UDDS, highway & US06 cycles. 
•	Studied the vehicle control strategies for HEVs and the CAN communication systems.
Modelling Simulation & Analysis of Series Hybrid Electric Vehicles in MATLAB
•Conducted benchmarking study of competitor vehicles with reference vehicle and developed preliminary specifications for 2023 Nissan Frontier concept. Carried out research on future drive assistance systems, engine downsizing methods, safety and security technologies. Developed pugh diagrams to highlight the acute superiority of 2023 target vehicle concept.

•Translated customer needs into functional specification through QFD application, developed interface diagram and matrix between various automotive systems, cascaded vehicle attributes requirements to the sub-system level.

•Developed V-Model timing plan and gateways, estimated cost curves and project profits. Formulated a Business plan for the 2023 concept vehicle and sketched the conceptual design.
Product Development of MY 2023 Mid-Size Pickup Truck
UNDERGRADUATE THESIS
•	Engineered a straight through absorptive type muffler that uses water, activated charcoal pellets and ceramic fiber wool for exhaust emissions and noise control.
•	Performed emissions and acoustic tests on the new Aqua exhaust and compared the results with the existing manufacturer-exhaust system data.
Development of Aqua Silencer for Two Wheeled Vehicle
•	Led a team of 25 engineers in the development of an All-Terrain Vehicle (ATV) based on SAE standards.
•	Designed vehicle space frame chassis and body using CATIA & UG/NX by collecting the necessary anthropometric dimensions of the ATV driver.
•	Designed lightweight and efficient drivetrain for the ATV by collaborating with the powertrain team.
•	Designed and developed brake disc and brake pedal assembly along with brake biasing using balance bar.
•	Performed Design Failure Modes Effects Analysis (DFMEA) to analyze design and mitigate risk.
•	Performed vehicle level testing on test tracks and collected data to develop countermeasures.
•	Liaised with the business team to assist in marketing and make-or-buy decision making process.
•	Managed suppliers and optimized parameters like cost, delivery and quality of the purchased components.
•	Organized weekly meeting with the project sponsor and coordinator to communicate the project status updates.
Baja SAEINDIA 2016
Studied the effect on heat transfer rate of longitudinal rectangular fins when varying the length of the fin and diameter of circular perforations on fins.
Comparative Analysis of IC Engine Cooling Fins
Engineered PET bottle up cycler, a pocket size tool that can cut plastic ropes from PET bottles. This Frugal innovation was developed with a vision to reduce plastic pollution.
PET Bottle up cycler
This project involved designing a solar dryer with Phase Change Material (PCM) as thermal storage medium. This provides optimized 24/7 operation of dryer for preservation of agricultural product at constant temperature.
Commercial Development of Solar Driers Integrated with Phase Change Material
Education
Bhumi
https://www.linkedin.com/company/bhumiorg
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Volunteer
CADD Centre Training Services Private Limited
www.caddcentre.com
M141260421
Professional in Product Design and Analysis
https://www.caddcentre.com/caddVerification.php?ddac=NDI4NTY5
CADDAM Technologies Pvt. Ltd.
SSIT/CT/2013-14/057
AutoCAD
https://www.linkedin.com/in/aakash-kumar-ta
Irving, TX
AAKASH KUMAR
Account  Manager at Synchrony Systems Inc
https://in.linkedin.com/in/aakash-kumar-aa10364b
Delhi, India
Aakash Kumar
Business Analyst
https://in.linkedin.com/in/aakash-kumar-31a85594
Delhi, India
Aakash Kumar
Trade Sales Manager at HDFC Bank
https://in.linkedin.com/in/aakashvani17
Jamalpur
Aakash Kumar
Learning MERN Stack, Data Structures, Algorithms and Soft skills
https://de.linkedin.com/in/aakashksinghla
Berlin
Aakash Kumar
Data Analyst at idealo internet GmbH
CAD, CAE, FEM, Durability, MBD & Optimisation
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https://www.linkedin.com/groups/1785947
Automotive OEM Professionals
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https://www.linkedin.com/groups/85731
FCA - North America Careers
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https://www.linkedin.com/groups/3781050
Leadership & Leadership Development
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Elon Musk (Unofficial)
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https://www.linkedin.com/groups/7022690
Renewable Energy World
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https://www.linkedin.com/groups/2121068
UM-Dearborn Alumni
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https://www.linkedin.com/groups/49615
Front End of Innovation
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https://www.linkedin.com/groups/41615
TED: Ideas Worth Spreading - Unofficial
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https://www.linkedin.com/groups/138801
Disruptor League
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https://www.linkedin.com/groups/1953902
UM-Dearborn Job Club
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History Enthusiasts Group
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Leaders in Higher Education
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Hybrid, Electric, PEV, and PHEV Engineering Professional Group
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