Summary
Overview
Work History
Education
Skills
Websites
Timeline
Generic

Vivek Patel

Tustin

Summary

Mechanical Engineer with over 14 years of expertise in Product Design & Development, Manufacturing, and Prototyping. Proven track record of leading product development from concept to mass production, ensuring on-time delivery and adherence to rigorous validation standards. Recognized for strong analytical abilities and technical knowledge, excelling in data-driven environments while enhancing team processes for improved efficiency. Demonstrates proficiency in CAD software and a commitment to innovative solutions that reduce costs and elevate operational effectiveness.

Overview

18
18
years of professional experience

Work History

Staff Design Release Engineer

Rivian Automotive
Irvine
11.2024 - Current
  • Led the end-to-end design and development of interior overhead system for Rivian vehicles, driving the development from initial concept through successful production launch.
  • Collaborated cross-functionally with internal teams (Studio, Manufacturing, Quality) and external suppliers to ensure alignment and resolve system integration challenges.
  • Established and achieved critical targets for component performance, appearance, quality, cost, timing, and mass through diligent research and project management.
  • Developed comprehensive component requirements, technical specifications, and Design Verification Plans & Reports (DVP&R) to guide development and ensure validation.
  • Utilized Catia v6 for CAD development (2D sections, 3D studies), led design reviews, and established criteria for sourcing, prototyping, testing, and manufacturing.
  • Managed Engineering Bill of Materials (EBOMs) and engineering data releases according to program milestones, consistently applying a first-principles problem-solving approach.

Senior Engineer, Mechanical

Masimo
Irvine
02.2023 - Current
  • Designed manufacturable mechanical solutions in highly regulated industry for sensor and capnography devices, integrating electrical components like sensors, displays, and batteries.
  • Defined product requirements, established validation testing protocols, and reviewed designs for injection molds and other production tooling.
  • Utilized rapid prototyping techniques, coordinated with vendors for parts, and collaborated with manufacturing engineers to transfer designs to production.

Design Release Engineer

Rivian Automotive
Irvine
05.2021 - 01.2023
  • Led design & development of interior sub-systems (overhead, floor, cargo, storage), engineering built-to-print parts compliant with FMVSS/ECE regulations.
  • Executed engineering/packaging studies with studio designers, optimizing Class A surfaces for manufacturing feasibility, function, mass, and cost targets.
  • Developed interior trim master sections and detailed Bills of Materials (BOMs) including investment, piece price, materials, and mass for RFQs.
  • Performed validation planning (DVP&R), tolerance stack analysis (DFSS) for gap/flush alignment, and defined product structure considering trim/CMF.
  • Collaborated cross-functionally (Packaging, Ergonomics, Studio, Safety, Simulation, Manufacturing) to integrate systems and meet program milestones.
  • Researched, established & achieved targets for performance, appearance, quality, and timing.
  • Prepared engineering, design, and process validation plans, tolerance stack analysis utilizing DFSS for gap & flush alignment for perceived quality, product structure based on trim variants and CMF input, vehicle benchmarking, etc.
  • Worked collaboratively with vehicle packaging, ergonomics, homologation, user experience, ID/studio, vehicle line, safety, simulations, LVE, ADAS camera, audio, antenna, manufacturing, service, and other engineering teams.

Design Engineering Manager

Kasai North America Inc.
Troy
08.2019 - 05.2021
  • Spearheaded Tier-1 new model product development for the high-volume (3k+/week) 2023 Honda Pilot, successfully meeting OEM deadlines.
  • Managed and guided a team of 11 design engineers, setting technical direction based on customer needs, engineering standards, and regulatory requirements (FMVSS, ECE).
  • Oversaw key engineering activities including DVP&R, DFMEA, design reviews, APQP, PPAP, and PFMEA processes.
  • Coordinated extensively with Tier 2, tooling, and equipment suppliers, defining technical specifications and collaborating cross-functionally.
  • Drove manufacturing process innovation, achieving 100% automation for soft trim parts and eliminating spray adhesives through a low-emission hotmelt process.
  • Developed automated solutions for door trim seal application and reduced metal screw usage by over 80% to enhance automation reliability and efficiency.
  • Managed departmental adherence to ISO/IATF 16949 and customer SQM requirements, tracked KPIs, and integrated sustainable design principles.

Design Engineer III, Project Chief

Kasai North America Inc.
Dublin
10.2011 - 08.2019
  • Spearheaded end-to-end design and development for multiple high-volume interior (e.g., Door/Quarter Trims, Headliners) and exterior (e.g., Bumpers, Facias) vehicle programs, guiding them from concept through mass production.
  • Led the creation of digital layouts, master sections, and technical drawings, integrating DFM/DFA, SPC studies, and strategic attachment methods in collaboration with OEM teams.
  • Directed technical studies, design validations, and established specifications for manufacturing methods, resin selection, and soft materials, ensuring DVP&R closure pre-tooling.
  • Pioneered robust DFMEA practices within the organization and utilized CAE analysis (LS-DYNA) results to enhance product safety, usability, and performance.
  • Managed customer RFQs with cost/mass-efficient proposals, drove significant cost reduction initiatives, and resolved design/manufacturing issues through root cause analysis and ECNs.
  • Coordinated prototype builds using soft tooling, ensured key program milestone readiness (digital, prototype, production), and supported client interactions and business development.
  • Provided on-site supervision, mentored associates with technical guidance and performance reviews, and delivered targeted training.
  • Successfully delivered key programs, including interior trim development for Honda vehicles such as the 2016-2023 Pilot, 2017 Ridgeline, and 2019 Passport.

Design Engineer

Lorax Works LLC
Scottsdale
01.2009 - 10.2011
  • Designed intricate sculpture components using CAD (UG NX, CATIA V5), employing advanced surface modeling and GD&T documentation.
  • Validated designs through comprehensive analysis (CAE, stress, loads, weight) to ensure requirements were met.
  • Programmed and operated CNC machines, managed rapid prototyping, and developed/modified electro-mechanical systems and microcontrollers (C, Forth, Assembly).
  • Managed projects from planning and budgeting to order fulfillment, including prototype development and testing.

Bioreactor Development Technician

The Bio Design Institute & Polytechnic Campus, Arizona State University
Tempe
05.2007 - 08.2007
  • Developed sustainable photobioreactor designs (2,000L rooftop & benchtop scale) for Bio-Diesel production from genetically modified Cyanobacteria, piloting a future large-scale desert project.
  • Designed, modeled (SolidWorks), and structurally verified (ANSYS/COSMOS FEA) mechanical and electro-mechanical components and assemblies for bioreactor systems.
  • Managed design documentation (revisions, BOMs, POs), developed large-scale pond reactor concepts, and improved existing designs by analyzing failure modes.

Education

Master of Science - Mechanical Engineering

Arizona State University
Tempe, AZ
08.2009

Bachelor of Engineering - Mechatronics Engineering

Sardar Patel University
Gujarat, India
07.2006

Skills

  • CAD Software: CATIA V5/V6 (3DExperience), SolidWorks, UG NX, Pro-E
  • Geometric Dimensioning & Tolerancing (GD&T): Experienced application in design
  • Tolerance Stack-up Analysis: Expertise in performing and interpreting tolerance analyses
  • Programming & Simulation: MATLAB, Simulink
  • Programming Languages: C, C
  • Controls: PLC Programming & Ladder Diagrams
  • CAE Analysis Software: ANSYS, HyperView (For simulation - FEA, thermal, etc)
  • Product Development Lifecycle (NPD): Including prototype development and feasibility studies
  • Requirement Assessment & Product Performance Analysis: Defining and verifying product function
  • Design Verification & Validation (DVP&R): Planning and executing tests to confirm design meets requirements
  • Quality & Reliability Methods: DFMEA, DRBFM, Root Cause Analysis
  • Design for Manufacturability/Assembly (DFM/DFA): Including DFSS principles and designing for automation
  • Rapid Prototyping: SLA, SLS, DMLS techniques for creating functional prototypes
  • Technical Documentation: Creating specifications, test reports, and engineering documents
  • Bill of Materials (BOM) Management: Creating and maintaining accurate BOMs (eg, in Enovia)
  • PLM Software: Enovia (Managing product data through lifecycle)
  • Manufacturing: Injection Molding, Sheet metal, Machining, Joining Techniques (Adhesive Bonding, Ultrasonic Welding, etc)
  • Fit & Finish: Assessing and designing for aesthetic and assembly for perceived quality
  • Interior/Exterior Trim Expertise: Design and manufacturing of Hard and Soft Trim components
  • Trim Manufacturing Processes: Press Forming, IMG, Thermoforming, Vacuum Lamination, Compression Molding, Press Lamination, Cut & Sew
  • Production Support: Assisting with pre-production builds and mass production ramp-up
  • Project Management: Planning, tracking (MS Project, Gantt Charts)
  • Collaboration Platforms: JIRA, Confluence
  • General Software: AutoCAD, Microsoft Office Suite, Google Workspace, etc

Timeline

Staff Design Release Engineer

Rivian Automotive
11.2024 - Current

Senior Engineer, Mechanical

Masimo
02.2023 - Current

Design Release Engineer

Rivian Automotive
05.2021 - 01.2023

Design Engineering Manager

Kasai North America Inc.
08.2019 - 05.2021

Design Engineer III, Project Chief

Kasai North America Inc.
10.2011 - 08.2019

Design Engineer

Lorax Works LLC
01.2009 - 10.2011

Bioreactor Development Technician

The Bio Design Institute & Polytechnic Campus, Arizona State University
05.2007 - 08.2007

Master of Science - Mechanical Engineering

Arizona State University

Bachelor of Engineering - Mechatronics Engineering

Sardar Patel University

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