THIRUPATHI D
Sr. NPI Engineer
Farmington Hills,US
Summary
Engineering professional with 8 years of experience in automotive glazing, sealing systems, and closure system design, with a strong background in plastic parts, sheet metal, and generative shape design. Proven track record working with OEMs like Tesla, Canoo, Faraday Future, and Volvo, using tools such as CATIA, NX, Creo, SolidWorks, and Rhinoceros. Skilled in DFMEA, APQP, PPAP, DVP&R, GD&T, and CAE tools like MSC Apex, Marc Mentat, and Nastran, with hands-on experience in glass bending tooling and smart glazing technologies (PDLC, SPD, Gorilla Glass). Known for cross-functional collaboration, engineering change management, and driving projects from concept to production with a focus on quality, manufacturability, and process optimization.
Overview
9
9
years of professional experience
3
3
Certifications
Work History
Sr NPI Engineer
AGP eGlass Co
Canton, MI
11.2021 - Current
- Lead New Model Introduction efforts focusing on Added Value Operations for automotive glazing, sealing systems, and closure assemblies, including windshield, roof, backlight, door glass, and associated sealants, for programs at Tesla, Volvo, Canoo, and Faraday Future.
- Developed innovative glazing and sealing solutions, collaborating with cross-functional teams to drive prototype builds and series production launches, ensuring seamless integration with closures and BIW structures.
- Interfaced with Design, Manufacturing, Quality, and Supplier Engineering teams to deliver optimized designs for manufacturability (DFMA), cost, and performance, incorporating feedback loops for continuous improvement in glazing and sealing components.
- Designed and developed complete glazing and sealing assemblies, including primary/secondary seals, encapsulations, PU bonding zones, and carrier brackets using CATIA V5/V6, NX, and SolidWorks.
- Participated in Product Development Teams (PDTs) to provide design direction for glazing and closure interfaces, utilizing CAE feedback and structural sealing analysis for improved fit, NVH, and thermal expansion behavior.
- Working with PDLC, SPD and Gorilla Glass to achieve better results for e-vehicles.
- Executed APQP deliverables (DFMEA, PFMEA, DVP&R, Control Plans) for both glazing and closure sealing components, ensuring regulatory compliance (FMVSS 205, ECE R43), structural durability, and robustness of adhesive and gasket systems.
- Managed Engineering Change Notices (ECN/ECR), tolerance stack-up reviews, GD&T, and design feasibility studies across all glazing and sealing assemblies, especially at closure interfaces like tailgates and doors.
- Collaborated closely with Closure, BIW, and sealing teams to optimize the interface between glass, PU beads, seal extrusions, and body apertures, achieving Class A surface alignment, controlled gap/flush, and long-term weather sealing performance.
- Utilized SAP for BOM management, procurement tracking, and production planning of glazing and sealing components, ensuring alignment with vehicle build schedules and traceability of closure system materials.
Product Design Engineer
Carlex Glass America LLC
Troy, MI
08.2017 - 11.2021
- Design and development of windshields, body side glass, quarter windows and back windows, sunroof components for Ford, BMW, SUBARU, FCA, Honda and Nissan.
- Responsible for the design of flat template, photo tooling, glass bending tooling and glass press face fixture.
- Designed and analyzed 'Heater Grids', and 'Heater Decals' for Windshield and Backlites using Catia, MSC Apex, and MSC Marc Mentat.
- Interacted with the FEA team and performed root cause analysis of failures occurring on the test prototype.
- Initiated and coordinated implementation of Engineering Design Change management (ECO, ECN, ECR). Updated engineering issues in customer change management systems (WERS).
- Led cross-functional APQP activities from concept through production, ensuring product quality and process robustness by implementing key deliverables such as DFMEA, Control Plans, and PPAP documentation.
- Prepared 3D Models and detailed drawings of Parts and Assemblies including GD&T using CATIA, NX, Rhinoceros and Creo. Creating and Updating Bill of Materials (BOM) for Prototypes and Production Units.
- Assist in the development of 3D Wire Harness for Heated Wiper Park, Headliner, Camera and Rain sensor.
- Participated in cross-functional design reviews involving closures, glazing, and body-in-white to address interface challenges between glass components and closures, including wiper cowl, garnish molding, and tailgate sealing interfaces.
- Responsible for the design and development of Camera and Rain Sensor Brackets (Plastic).
- Manage design data within the Carlex internal PLM system and the customer PLM systems (FORD Teamcenter, NISSAN Teamcenter, PTC Windchill & FCA Teamcenter).
- Verify the design with clash and sectioning (Gap & Flush), modify if required.
Design Engineer
AutoTechMation Inc.
Farmington Hills, MI
06.2016 - 08.2017
- Responsible for 3-D Modeling, 2-D detailing and engineering changes for automotive exhaust manifolds using CATIA V5.
- Manage assigned projects including product improvements, product extensions, product enhancements, and new product development.
- Participate in Project Management activities; provide input to establish project development timelines.
- Design modifications as per the ECR requested by the client.
- Utilized PLM Teamcenter to improve manufacturing processes and to create workflow designs.
Education
Master of Science - Mechanical Engineering
Lawrence Technological University
Southfield, MI05.2016
Bachelor of Science - Mechanical Engineering
Jawaharlal Nehru Technological University
Hyderabad, TS05.2013
Skills
- CATIA V5, 3DX
- Siemens NX11
- Creo 40
- SolidWorks 2015
- AutoCAD 2014
- Rhinoceros 40
- MSC Apex V2018
- MSC Marc Mentat V2018
- MSC Nastran V2017
- Siemens Teamcenter
- PTC Windchill
- Minitab
- ERP
- Python
- MS Office Suite
Certification
Six Sigma Green Belt
Expertise
APQP, DFMEA, GD&T, PPAP, DFMA, DVP&R, VAVE, DFSS, DOE, SPC, MSA, Ford Wers, Nissan Tcp2, SAP, Glass Bending Tooling, Fixture Design
Timeline
Sr NPI Engineer
AGP eGlass Co
11.2021 - Current
Product Design Engineer
Carlex Glass America LLC
08.2017 - 11.2021
Design Engineer
AutoTechMation Inc.
06.2016 - 08.2017
Master of Science - Mechanical Engineering
Lawrence Technological University
Bachelor of Science - Mechanical Engineering
Jawaharlal Nehru Technological University
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