Darshini Nanthagopal

• Led product development projects from concept through final delivery, managing sheet metal and plastic component designs, BOM structuring, and manufacturing drawings for various products, including Marine Air Conditioners, Refrigerators, and RV Ovens
• Proficient in SolidWorks, CATIA, and CREO for 3D modeling, surface design, and detailed 2D drafting, ensuring manufacturability, assembly optimization, and alignment with client requirements
• Guided a 4-member team to deliver high-quality designs and technical reports, collaborating with industrial design, manufacturing, and customer teams to meet project objectives and deadlines
• Extensive experience in tolerance stack-up analysis, harness development, and electrical schematic layout design, including the selection of sensors, connectors, and wiring based on UL ratings
• Applied reverse engineering and VAVE techniques to reduce material costs, enhance design efficiency, and streamline production work flows, resulting in significant cost savings
• Applied advanced tools such as GD&T, finite element analysis (FEA), and statistical analysis to optimize design performance, ensure structural integrity, and enable data-driven decision-making

Projects Handled :

• Performed teardown analysis of customer and competitor refrigerators for cost and performance benchmarking, developed cost-reduction strategies, optimized manufacturing feasibility, and collaborated with the electrical team to redesign the refrigeration harness, achieving a 10% cost reduction and improved performance
• Developed and redesigned caravan fans, improving tooling compatibility, aesthetics, and efficiency with a 20% increase in airflow efficiency through DFMEA, FEA, and industrial design collaboration
• Reverse-engineered and optimized complex air heaters and boilers, achieving a 15% cost reduction and enhanced performance in collaboration with FEA teams for thermal and CFD analysis
• Led the Material Substance Control project by collecting and verifying supplier data using a standardized template, ensuring compliance with global regulations (e.g., RoHS, REACH) and internal sustainability standards
• Collaborated with suppliers and internal teams to streamline material selection and mitigate compliance risks
• Designed and developed an IP67-rated plastic enclosure for a modem using SolidWorks, ensuring waterproof specifications and applying plastic engineering principles for durability and manufacturability
• Managed the Migration & Sustenance Project by converting legacy CAD files into new parametric models using Creo and CATIA, ensuring design compatibility, standardisation, and alignment with customer specifications.

• Gained hands-on experience in production techniques and quality control protocols by actively engaging in the plant environment and assisting in various shop-floor activities
• Tracked trainee performance data, providing insights to enhance future training curriculum and improve operational efficiency
• Shadowed senior team members to learn critical tasks and processes, building a strong foundation in automotive manufacturing practices