Chitharanjan Ganesh Kumar

Performed data collection, testing, and performance analysis of electrostatic clutches to drive design improvements and validation. Executed design iterations and prototyping of electrostatic clutches, applying DFMEA, DFM, and DFA to improve reliability and manufacturability. Developed and debugged Python and MATLAB automation tools for clutch testing and automated report generation, improving test efficiency and consistency. Led the design and development of a fully automated test stand, including fixture design, motor/gearbox and shaft selection, electronics integration, and control scripting. Authored standardized test protocols to support repeatable validation and production testing. Served as Interim Production Manager, overseeing component sourcing, assembly, testing, and on-time delivery of customer clutch units under tight deadlines.

Designed and optimized powertrain components, including motors and gearboxes, improving production efficiency by 15%. Led cross-functional teams to integrate powertrain systems into two-wheeler EVs. Managed production drawings, BOMs, and conducted tolerance analysis for mass production. Developed DFMEA and DVP documentation for electric motors and gearboxes. Prototyped and tested reduction gearboxes, ensuring quality through endurance testing

Designed and analyzed drivetrain components (shafts, gears, axles) using CATIA V5 and KISSsoft for BAJA racing cars. Developed and tested a force multiplication mechanism in the primary clutch of Continuous Variable Transmission (CVT), optimizing performance. Performed vehicle dynamics calculations to enhance car performance and conducted FEA on drivetrain parts using ANSYS. Engineered a tubular chassis, ensuring structural integrity and safety compliance. Collaborated in composite manufacturing for lightweight car components like the steering wheel and body panels.