Amar Jadhav

• Vehicle Architecture & Launch: Led the engineering and launch of 5+ automotive structural programs for major OEMs (Ford, GM, Honda), delivering custom structural solutions that met strict first-mode stiffness, crash safety, and packaging requirements.
• Trade-off Analysis & Optimization: Developed detailed trade matrices to evaluate design concepts against weight, cost, and package volume constraints. Successfully engineered a lightweight bumper design that reduced mass while maintaining performance, earning recognition as a 2022 Altair Enlighten Award finalist.
• Class-A Surface Integration: Engineered structural bumper beams and sub-frames to accommodate tight Class-A styling constraints, working closely with studio teams to ensure structural hardpoints did not compromise vehicle aesthetics or gap-and-flush targets.
• OEM & Supplier Collaboration: Served as the primary technical interface between OEM engineering teams and Tier 1 manufacturing partners. Managed supplier downselection and readiness, conducting on-site reviews to resolve DFM feedback and ensure alignment with production intent.
• Manufacturing Process Development: Engineered high-integrity hardware utilizing castings, extrusions, and stampings. Collaborated with tool shops to optimize tooling design for investment cost and part quality, directly contributing to the 2021 Casting of the Year Award.
• Quality & Validation: Owned the PPAP and validation process for critical safety components. Implemented advanced Red X problem-solving methodologies to identify root causes of failure, improving manufacturing tact time and reducing failure rates by 10%.
• Innovation: Inventor of a patented bumper beam design (WO/2017/015482), demonstrating ability to create novel solutions for complex vehicle packaging challenges.

• Concept Validation: Modeled and validated vehicle structures using FEA (LS-DYNA, Nastran) to ensure designs met crashworthiness and stiffness targets prior to tooling kickoff.
• Design Optimization: Utilized topology optimization tools (HEEDS, Optistruct) to drive material reduction strategies, achieving significant mass savings across multiple vehicle platforms.

Gained hands-on experience in component design and simulation, supporting senior engineers in validating structural performance.