Senior Mechanical Design Engineer
2024-Present
Skillset
CATIA V5 / V6/ 3DX
Parametric CAD Modelling and Boolean Operations
High Volume Manufacturing Design
Automotive Safety Standards (FMVSS, IIHS, E/CN-NCAP)
Human Centric Design
Design for Manufacturability and Assembly (DFMA)
Finite Element Analysis (FEA)
Tolerance Analysis (TA)
Design of Experiments (DoE)
Roles and Responsibilities
2 x Patents filed related to automation. Projected to save ~2500 man-hours/year.
Led the development of interior trim components from hand sketches to mass production across 2.5 years without delays.
Invented an industry-first interior door panel designed for 100% automation. Presented work to Vice President (Patent Pending).
Invented a low-profile trim-clip that unlocks automated assembly in tight spaces (Patent Pending).
Collaborated with vendors to apply AI & 3D vision systems for robotic trim install and defect inspection.
Led design reviews with the Chief Engineer and Chief Studio Designer to define design intent and balance it with key performance metrics: Safety, mass manufacturability, sustainability, cost, mass, ergonomics, quality, and craftsmanship.
Spent 2-months in China to oversee high volume ramp and resolve quality issues (Fluent in Mandarin).
Prepared RFQ packages for supplier selection; created "Should Cost" calculators to vet supplier quotes.
Defined datum and attachment strategies using Tolerance Analysis. Used GD&T to create 2D drawings and fixtures.
Leveraged parametric CAD modeling and Boolean operations to speed up iterative design process 5x.
Interviewed, hired and mentored interns and junior engineers.
Charlie Lim 2026