LOHITH PRABHAKAR
Brookville,OH
Summary
Design Engineer with extensive experience at Green Tokai Co., LTD, specializing in CATIA V5/V6 and design optimization. Consistently delivered 100% on-time results across 14+ programs, enhancing team collaboration and problem-solving capabilities. Proficient in GD&T and rapid prototyping, contributing to increased efficiency and innovation in automotive component design.
Overview
6
6
years of professional experience
Work History
Design Engineer
Green Tokai Co., LTD
Brookville, OH
02.2023 - Current
- Designed 23+ exterior components (seals, moldings, pillar trim) for Honda and Toyota using CATIA V5/V6 (3DX).
- Performed 3D modeling, assemblies, surfacing, GD&T drawings, BOM, DFMEA, and tolerance stack‑up.
- Led 14+ full lifecycle programs ensuring 100% on-time delivery and zero design-related delays.
- Reduced design iterations by 25% through advanced optimization and design troubleshooting.
- Collaborated with suppliers for prototyping, validation, and packaging feasibility studies.
- Used 3D printers/resin printers to reduce development cycle time by 20% and prototype errors by 30%.
- Conducted material selection, manufacturability analysis, and structural integrity reviews.
Graduate Teaching Assistant
Wright State University
09.2022 - 12.2022
- Conducted 5 vibration testing labs per semester with 95% successful completion rate.
- Taught Abaqus for 3D/2D modeling, meshing techniques, load application, and post-processing.
- Provided hands-on support to 40+ students for FEA problem-solving.
- Delivered accurate grading and maintained 100% on-time submission.
International Check‑In Coordinator
Wright State University
01.2022 - 08.2022
- Handled intake and support for 200+ international students.
- Managed 30 volunteers and coordinated with 50+ mentors during Orientation Week.
- Ensured smooth onboarding and compliance procedures for new students.
Independent Research Assistant
Wright State University
04.2022 - 07.2022
- Performed JEDEC-based drop reliability assessments on PCB assemblies.
- Completed 50+ drop tests and identified 20% improvement opportunities.
- Designed custom drop‑test equipment using SolidWorks saving $5,000 in outsourcing.
- Performed CNC machining operations achieving 100% dimensional accuracy.
- Validated FEA results with 98% correlation using ASTM E399 standards.
Mechanical Engineer Intern
Rajlakshmi Industries
09.2019 - 02.2020
- Operated CNC machines and improved productivity by 20%.
- Interpreted mechanical drawings and ensured 100% dimensional accuracy.
- Reduced waste by 10% through improved machining processes.
- Collaborated with vendors to meet manufacturing timelines.
Education
Master of Science - Mechanical Engineering
Wright State University
Dayton, OH01.2022
Bachelor of Science - Mechanical Engineering
Dayananda Sagar University
India01.2019
Skills
- CATIA V5/V6 (3DX)
- SolidWorks
- NX Siemens
- CREO
- Fusion 360
- Autodesk Inventor
- AutoCAD
- Revit
- Abaqus
- Ansys
- HyperWorks
- GD&T
- DFMEA
- PFMEA
- Tolerance Stack‑up
- 3D Printing (FDM, Resin)
- Rapid Prototyping
- Injection Molding
- Plastic Extrusion
- Rubber Components
- CNC Machining (Milling, Drilling, Threading)
- Jig & Fixture Design
- Tooling Design
- Problem Solving
- Root Cause Analysis
- Design Optimization
- Packaging Feasibility
- Python
- MATLAB
- Simulink
- MS Office
- Minitab
- Automotive Standards: JEDEC
- ASTM Standards
- DOE
- SPC
- PPAP Documentation
Projects
Honda B‑Pillar Garnish (3MJA & 3MKA), Developed 3D CAD models using CATIA V5 and annotated drawings in CATIA V6 (3DX)., Collaborated with Honda R&D resulting in 15% improvement in structural performance., Completed design deliverables 2 weeks ahead of schedule., Resolved 3 major design conflicts before production. Honda 3BMA Roof Garnish – Jig Fixture, Designed 3D‑printed jig fixture reducing defects by 15%., Increased testing measurement accuracy by 20%., Reduced jig fabrication cost by 40% using in-house 3D printing. Toyota Quarter Window Seal – Length Check Fixture, Reduced inspection time by 35% across 3 product variants., Achieved ±0.1 mm accuracy using CMM verification., Saved $15,000 by eliminating outsourcing; reduced lead time by 50%. PPE Using Additive Manufacturing, Reduced PPE manufacturing time by 40% via design simplification., Improved comfort by 30% through ergonomic designs., Produced 100+ units distributed to 5 hospitals.
Timeline
Design Engineer
Green Tokai Co., LTD
02.2023 - Current
Graduate Teaching Assistant
Wright State University
09.2022 - 12.2022
Independent Research Assistant
Wright State University
04.2022 - 07.2022
International Check‑In Coordinator
Wright State University
01.2022 - 08.2022
Mechanical Engineer Intern
Rajlakshmi Industries
09.2019 - 02.2020
Master of Science - Mechanical Engineering
Wright State University
Bachelor of Science - Mechanical Engineering
Dayananda Sagar University