Summary
Overview
Work History
Education
Skills
Awards
Sae Experience
Timeline
Generic

Abhilash Reddy Babu Reddy

ROCHESTER HILLS,MI

Summary

Automotive engineer with 6 years of experience specializing in low voltage wiring harnesses, brake systems, CATIA design optimization, supplier negotiations, cost/weight optimization, and weight audits. Strong leadership skills in cross-functional teams and high-pressure environments. Currently leading prototype wiring system development for multiple Stellantis EV programs, including vehicle electrical architecture, wiring harness design, BOMs, and schematics. Managed engine bay and door harnesses for Ford Escape’s AV program, overseeing day-to-day assembly operations at the prototype build phase. Spearheaded the design and release of brake systems (hose, harness, and engine room pipes) for Honda Acura, optimizing layout for safety, cost, weight, and investment. Led prototype layout verification at Honda, conducting technical evaluations and layout signoffs. Developed procedures, templates, and training modules for weight/mass calculations across various load conditions. Ran option weight calculations for Ford’s Lightning program. Technical Skills: CATIA V5, ABAQUS, DVP&R, MATLAB, DFMEA, GD&T, TEAMCENTER, ENOVIA.

Overview

12
12
years of professional experience

Work History

Sr Prototype Wiring Systems Engineer

Stellantis
09.2022 - Current
  • Design and release prototype low voltage wiring harness layouts, including cutsheets, 3D/2D drawings, and component procurement for harness reworks
  • Develop CAN and LIN communication wiring to ensure seamless module integration
  • Create and maintain detailed BOMs, connector pinout sheets, napkin diagrams, and schematics to support prototypes
  • Collaborate with Prototype Build Engineering to resolve wiring issues, perform debugging, and implement electrical changes during vehicle builds
  • Lead on-vehicle wiring design changes, providing clear, step-by-step update procedures
  • Generate CAD drawings and supplier markups based on 3D models, detailing clipping points, splice locations, branch takeouts, and donor harness modifications

Lead Wiring Harness Engineer – Autonomous Vehicles

Ford Motor Company
02.2022 - 08.2022
  • Designed and developed electrical distribution systems (EDS) for a driverless autonomous vehicle program
  • Reviewed and validated 2D schematics, 3D drawings, and supplier prints, ensuring design accuracy and feasibility
  • Supported 3D/2D CAD manufacturing data review using CATIA, SharePoint, and Teamcenter
  • Led onsite prototype build activities, addressing assembly concerns, and part quality assessments
  • Collaborated with suppliers, plant engineers, and assembly teams to troubleshoot and resolve production issues
  • Conducted final prototype build inspections, ensuring proper routing, safety compliance, and full system functionality before approval

Brake Design Engineer II

American Honda Motor Company, Inc.
04.2021 - 02.2022
  • Led layout verification checks and prepared documentation for design reviews, technical evaluations, and approvals
  • Collaborated with manufacturing engineers and cross-functional teams to support prototype builds at the factory
  • Managed part schedules and design review meetings, coordinating with suppliers, purchasing teams, and cross-functional stakeholders to assess lead times, cost implications, and program timelines, while presenting part maturation progress to management
  • Conducted feasibility studies, including weight calculations, validation tests, and component cost analysis to optimize designs

Weight Engineer

Ford Motor Company
11.2019 - 04.2021
  • Supported global Ford programs by developing processes and tools to achieve efficient mass designs
  • Collaborated with vehicle program teams to collect and analyze measured vehicle data (foundation curb weight, options weight, and payloads) from plant scales, generating Vehicle Audit Reports
  • Utilized Six Sigma tools for analytical calculations, predicting trends, and making data-driven recommendations based on audit analyses
  • Conducted benchmarking studies, gathering competitor data from various databases to forecast weight attribute performance, emerging technologies, and industry trends for future programs
  • Developed procedures and templates for nonstandard loading conditions, including snowplow calculations, non-trailer hitch receiver conditions, and frunk loading for EVs
  • Partnered with fuel economy, aerodynamics, and homologation teams to ensure accurate payload, GVWR, and GAWR values for vehicle labeling compliance

Brake Design Engineer I

American Honda Motor Company, Inc.
11.2018 - 09.2019
  • Designed 3D CAD models for brake hose and ABS harness routing across all suspension and steering conditions, ensuring compliance with internal design standards and federal regulations using CATIA V5
  • Conducted on-car validation for prototype vehicles, resolving clearance issues with innovative countermeasures to meet company requirements
  • Optimized braking system cost and weight, implementing bolt commonization, part interchangeability, and the development of isolation brake pipe clips, while negotiating with suppliers for cost efficiency
  • Performed competitive benchmarking, analyzing new brake system technologies to align with market trends and enhance design strategies

Student Ambassador

University of Michigan Dearborn
01.2017 - 05.2018
  • Worked with Student Leaders, organizations, and external clients to plan and manage events and activities on campus
  • Gave freshmen open house tours, presentations, and international graduate student orientations

SAE BAJA – Design Team Lead

06.2014 - 01.2015
  • Optimized pedal box for weight reduction and design of Adjustable pedal box
  • Organized weekly team meetings to oversee the progress of the individual design teams and be a bridge between design teams and manufacturing teams to ensure their smooth and successful functioning
  • Presented the team progress, ideas, budget report and project schedule to the school management and sponsors

SAE International Go Kart Championship – Brake Team Lead

08.2013 - 04.2014
  • Led the Brake team group meetings and presented it to the Team leader and manufacturing groups on a weekly basis
  • Route the brake hose and pipes to maintain a safe distance from moving and static components

Education

Master of Science - Mechanical Engineering

University of Michigan Dearborn
Dearborn, MI
01.2018

Bachelor of Science - Mechanical Engineering

Sri Venkateshwara College of Engineering
Bangalore,India
01.2016

Skills

  • CATIA V5
  • ABAQUS
  • DVP&R
  • MATLAB
  • DFMEA
  • GD&T
  • TEAMCENTER
  • ENOVIA

Awards

  • BEST STUDENT MANAGER AWARD: Recognized for my efforts as manager at the University’s Cultural Festival.
  • GRADUATE STUDENT SCHOLARSHIP (UM of Dearborn): Granted for maintaining a 3.3 GPA or higher.
  • EMERGING STUDENT LEADER AWARD (UM of Dearborn student activities)
  • ONE FORD (Ford Motor Company)

Sae Experience

  • SAE BAJA – Design Team Lead, 06/14, 01/15, Optimized pedal box for weight reduction and design of Adjustable pedal box., Organized weekly team meetings to oversee the progress of the individual design teams and be a bridge between design teams and manufacturing teams to ensure their smooth and successful functioning., Presented the team progress, ideas, budget report and project schedule to the school management and sponsors.
  • SAE International Go Kart Championship – Brake Team Lead, 08/13, 04/14, Led the Brake team group meetings and presented it to the Team leader and manufacturing groups on a weekly basis., Route the brake hose and pipes to maintain a safe distance from moving and static components.

Timeline

Sr Prototype Wiring Systems Engineer

Stellantis
09.2022 - Current

Lead Wiring Harness Engineer – Autonomous Vehicles

Ford Motor Company
02.2022 - 08.2022

Brake Design Engineer II

American Honda Motor Company, Inc.
04.2021 - 02.2022

Weight Engineer

Ford Motor Company
11.2019 - 04.2021

Brake Design Engineer I

American Honda Motor Company, Inc.
11.2018 - 09.2019

Student Ambassador

University of Michigan Dearborn
01.2017 - 05.2018

SAE BAJA – Design Team Lead

06.2014 - 01.2015

SAE International Go Kart Championship – Brake Team Lead

08.2013 - 04.2014

Master of Science - Mechanical Engineering

University of Michigan Dearborn

Bachelor of Science - Mechanical Engineering

Sri Venkateshwara College of Engineering
Abhilash Reddy Babu Reddy