Udaykumar Borale
R&D Engineer — Powertrain & BIW Specialist
Results-driven R&D Mechanical Engineer with expertise in automotive and industrial automation, specializing in powertrain design, BIW systems, and advanced CAD/CAE — transforming concepts into production-ready solutions.
Who I Am & What I Do
I'm a passionate Mechanical Design and Simulation Engineer with expertise in powertrain engineering, BIW design, and advanced CAD/CAE. I transform complex engineering challenges into innovative, production-ready solutions.
My work spans concept development, detailed design, FEA validation, and manufacturing support — ensuring every product meets the highest standards of performance, safety, and efficiency.
Research-Driven Engineering & Design Optimization
Results-driven R&D Mechanical Engineer with expertise in the automotive and industrial automation sectors, specializing in mechanical product design, powertrain systems, and engineering development.
Experienced in managing the complete product development lifecycle, from concept generation to production readiness.
Strong background in research-driven engineering and design optimization, leveraging advanced simulation and modeling techniques.
Engineering Tools & Technologies
Proficient in industry-leading software for design, simulation, and analysis.
1000+ production-ready CAD models delivered
15% assembly time reduction through DFM/DFA optimization
10% weight reduction via lightweight design strategies
What I Excel At
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Design Excellence
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Advanced 3D modeling using CATIA, SolidWorks, PTC Creo, Siemens NX, and Autodesk Inventor.
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Simulation & Analysis
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Comprehensive FEA using ANSYS, ANSA, HyperMesh, and MATLAB. Specializing in Static, Modal, Thermal, Fatigue, and Structural Validation.
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Automation & R&D
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End-to-end product development, BOM management, PLM/PDM workflows, robotic automation, and compliance with IATF 16949 standards.
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Work Experience
Professional journey and key achievements
- Advanced engineering and R&D company focused on automotive and automation systems, specializing in Powertrain & BIW components, product concept development, detailed design, and validation.
- Spearheaded the design and development of Powertrain components, significantly enhancing structural integrity, performance, and manufacturability.
- Developed 1000+ production-ready 3D CAD models and large-scale robotic deburring station assemblies (400–500 components) using Autodesk Inventor, integrating mechanical subsystems and optimizing designs for manufacturing and assembly.
- Optimized mechanical assembly design using DFM/DFA principles, reducing assembly time by 15% and improving manufacturing efficiency.
- Implemented lightweight design strategies through CAD optimization and structural analysis, achieving 10% reduction in component weight while maintaining performance requirements.
- Improved engineering workflow efficiency by optimizing CAD modeling, design validation, and documentation processes, reducing overall design cycle time by 20%.
- Conducted FEA simulations using ANSYS, Autodesk Nastran, NX Nastran, and HyperMesh for structural validation, stress analysis, failure identification, and component performance optimization.
- Applied DFM/DFA principles to reduce weight, minimize cost, and enhance manufacturability.
- Collaborated with manufacturing, quality, procurement, and engineering teams to deliver first-pass approved designs aligned with manufacturability, quality standards, and production requirements.
- Ensured compliance with global automotive standards and embraced Industry 4.0 practices to optimize manufacturing processes.
- Created detailed 3D models and simulations to support product design initiatives.
- Assisted QA processes to meet industry standards and improve product reliability.
Internship & Training
Bajaj Engineering & Skills Training
Mechatronics & Automation Trainee
Six-month residential program focusing on motion control, robotics, PLCs.
CONCEPTIA KONNECT
Simulation & Structural Analysis
Training in ANSYS, SolidWorks and PTC Creo.
PRIME TOOLING
Design & Structural Analysis
Intensive training in precision engineering and CAD/CAM.
CNC Machines – Bharat Fritz Werner
Machining & Manufacturing
Practical exposure to CNC machining processes.
BELATHUR INDUSTRIES
Machining Operations
3D modelling using CATIA V5; assisted in process optimization.
Bosch – Diesel Services Division
Intern (CFD & Flow Simulation)
Fluid flow simulation with ANSYS Fluent and SolidWorks.
Key Industry R&D Projects
Industrial research projects in mechanical design, automation, and CAD/CAE validation.
Robotic Deburring Station – Cylinder Block Machining Automation
Customer: Cummins India Ltd. — Chropynska India Pvt. Ltd. | Oct 2025 – PresentDesigned and developed a robotic deburring automation system for heavy-duty engine cylinder blocks (KV/QSK60 variants), integrating robotic machining, material handling, and automated manufacturing solutions.
- Developed 3D CAD assemblies, machine layouts, and mechanical concepts for major subsystems including loading/unloading shuttle, conveyor mechanism, turntable with lifter, robot cell structure, tooling fixtures, and safety enclosure.
- Performed FEA-based structural analysis and design validation using CAE tools to evaluate component strength, identify critical stress regions, validate mechanical designs, and optimize structural performance.
- Conducted design analysis activities including CAD interference checks, assembly feasibility analysis, tolerance verification, and engineering validation to ensure reliable system integration.
- Supported integration of KUKA & Fanuc robotic systems, dry deburring tools, brush holder mechanisms, and brush wear detection fixtures for automated surface finishing operations.
- Designed mechanical solutions considering component handling, orientation, fixture design, accessibility, manufacturability, and production workflow requirements.
- Worked on industrial safety integration including machine fencing, light curtains, area scanners, sliding doors, and safety locking systems.
- Prepared assembly models, engineering drawings, technical documentation, and design review inputs for customer and cross-functional engineering discussions.
- Applied DFM/DFA, GD&T, tolerance analysis, and design optimization principles to improve system reliability, operator safety, and manufacturing readiness.
Academic Research Projects
Engineering research in FEA, simulations, renewable energy, and thermal engineering.
Lightweight E-Axle Design & Optimization for EV
Apr – Jul 2024Engineered a lightweight electric axle for EV applications.
- Complete e-axle housing geometry developed.
- Structural FEA for torque reaction loads.
- Topology optimization reduced mass.
Modeling and Analysis of Vertical Axis Wind Turbine Blade
Apr – Jul 2024Designed a Savonius-type VAWT blade.
- Developed complete 3D blade geometry.
- Performed FEA to analyze stress and deformation.
Free Convection in a Trapezoidal Cavity with Porous Media
Aug – Dec 2024FEM-based numerical simulations to analyze natural convection.
- Performed FEM-based thermal and flow simulations.
- Analyzed Rayleigh number and porosity effects.
Skills & Tools
Expertise in industry-leading engineering tools and technologies
3D Modeling Tools
Simulation Software
Product Development
Certifications
Education
Academic background and qualifications
Master of Technology (M.Tech)
Engineering Design
Symbiosis Institute of Management Studies, Pune
Bachelor of Engineering (B.E)
Mechanical Engineering
Bangalore Institute of Technology, Bengaluru
Diploma
Mechanical Engineering
Jawaharlal Nehru Polytechnic, Bidar
Let's Work Together
Ready to bring innovative engineering solutions to your next project.