# Bhushan Zambre > Product design, Seat structure design, Seat complete, Plastic design, ED&D Professional Location: Fremont, California, United States Profile: https://flows.cv/bhushanzambre An Engineering Professional Passionate about work and Technology, Have around 15+ years of experience in Automotive Seating and Components Design, Have hands on, Team Management, APQP, DFSS,FMEA. experience on CATIA, Unigraphics- NX, NX Kinematics,Teamcenter, Agile, Sucessfully Designed Seat Frame-Structure, Seat Plastics and Complete Seat Design, With Global long-term work Experience in Germany and in USA, Looking for Challenging work in the relevant filed, USA H1B and B1 Visa Holder ## Work Experience ### Sr. Engineer Complete Seat @ Lucid Motors Jan 2024 – Present | Newark, California, United States Working as Senior engineer seating’s for Gravity Row2 complete seat department  Supporting DV actives, Solving issues occurred during DV1, DV2, and handling preparations for SOP  Leading member in Communication, ED&D, DVPR and testing activities with Seat Frames, JIT Suppliers  Problem solving through one pager, A3, 5Y techniques, Lucid cross functional team interface reviews  Quick and feasible design proposals for seat structures, Plastics etc. in CAD (CATIA), 3Dx  Prototyping, packaging and evaluating with higher management reviews using 3D printing, Cut&weld concepts, assemblies of the newly proposed ideas ### Design Release Engineer @ Rivian Jan 2023 – Jan 2024 | Irvine, California, United States • New product concept, benchmarking for seating structure, requirement mapping, design, feasibility, costing, timeline optimization • Working on front and rear seat structure components and assembly, proposals, design, mechanisms • Directing CAD team for the required and feasible 3D and 2D of seat structure components and ASM • Product documents creations such as BOM, weight optimization matrix, product book presentations • Carry the CAE supporting activities from input to results analysis and action plan creation, • Leading the Cut&Weld, mule build of seat structure design, manufacturing, and physical build, • Carry all the cross functional teams activities such as reviews, ICD preparation and signoff • Prepare and implement DFSS requirements such as DFM, DFA, tolerance stackups, forming analysis, welding feasibility, GD&T optimization, fixture concurrence, • DVPR, DFMEA creation and making sure all the regulatory, durability, due care, performance testing completed and meeting successfully, ### Project Lead @ Tech Mahindra Jan 2024 – Jan 2024 | Pune, Maharashtra, India #Leading the Design and Engineering for Project-X Front Row Complete Seating Projects. #Performing Front Complete Seat, Seat Structure Benchmarking, Complete Seat BOM and SOR Creation, #Presented Initial Timeline and gates for Seat D&D, Created Initial DVP per the Launch Market (ECE & AIS Std.) and OEM Specifications, RASIC chart preparation and Signoffs. #Seat CAS data study for Styling Feasibility, Seat CAS data Packaging study with environment, Prepared Complete Seat and Components Checklist per the Regulatory and OEM Guidelines #Handling Customer communication, Data Management, Task Distribution, Design Review and final output submission. ### Product Design Engineer @ Faurecia Jan 2020 – Jan 2022 | Pune, Maharashtra, India #Client site at Faurecia Automotive Seating #Worked on Complete Seat and Seat Components Design, effectively managed the team, Clients- Daimler, Renault #Successfully Accomplished: The Seat Packaging, ECE Regulations Study and Implementation, Comfort-M To M Study, Seat Tolerance Stackups #Concept Design for Seat Frames-Structures and components such as Back Panel, Cushion Pan, Side members and Plastic Parts of Seat per the manufacturing #Worked on complete seat BOM, Product book creation, Components and ASM weight calculation #Carrying Seat Spare Parts Activities by maintaining S-BOM with PLM tools #Proficiently worked with CAD Softwares CATIA, UG-NX, ### Lead Design Engineer @ Magna International Jan 2018 – Jan 2020 | Pune, Maharashtra, India #Worked on Seat Structure Design, effectively managed the team, Client Chrysler #Successfully Accomplished: Seat Frame Design, Concepts with manufacturing feasibility and VAVE #Designed Back panel, Cushion pan, side members Recliner ASM, #Prepared Structural components and ASM, drawings from Proto Build to Production release with Structural Guidelines, GD&T, datum schemes, SC, CC , Welding specs, Identification of various zones, Manufacturing-Feasibility sign-off, #Done forming analysis, Prevention control Studies, Tolerance stack-ups Creation, kinematics Creation, BSR section analysis, weld gun Access studies, sheet metal Guidelines study, BOM creation, carries Customer and supplier Meetings Part of DVPR, DFMEA process and Activities #Proficiently worked with CAD softwares CATIA, UG-NX ### Sr. Design Engineer @ Commercial Vehicle Group, Inc. Jan 2016 – Jan 2018 | Pune, Maharashtra, India #Worked on Complete Seat and Seat Components Design for Client Navistar #Sucessfuly Accomplished: The Design and engineering of Complete Seat, Frames components such as Seat back Profiles, Cushion Pan, Mounting Brackets and Tubular components with cushion tilt and slide mechanism and Kinematics #Plastic Components Design such as Side Shields, Covers, #Part of DVPR, DFMEA process and Activities Part of legal/Regulatory and durability tests such as Seat belt anchorage test, BSR test, ingress egress test, Seat Track durability test, Seat back strength test, Head Restraint performance test #Proficiently worked with CAD softwares CATIA, UG-NX ### Product Engineer @ Adient Jan 2010 – Jan 2016 | Pune, Maharashtra, India #Worked on Complete Seat Design for Client Opel, GM, Daimler #Successfully Accomplished: Activities from RFQ to SOP, includes CAD proposals, 3D modelling from styling data Sheet Metal and Plastics Parts modelling and drawing creation as per GD&T, Seat Wire Harness Design and developing 2D electrical schematics, #Complete seat Safety, MTM, Packaging studies per ECE, FMVSS Regulations, Successfully completed several Proto-build and part of physical testing at JCI JIT plant Burscheid, Germany, part of Delta 8WP FS physical build Deputed to Burscheid Germany at Johnson controls GmbH, worked as Design Engineer with Complete seats GMBU for 2 years. #Proficiently worked with CAD Softwares CATIA, UG-NX ## Education ### CAD in CAE Diploma, Engineering Design CAD CAM Guru Jan 2009 – Jan 2009 ### Bachelor of Engineering (BE) in Mechanical Engineering Amravati University Jan 2003 – Jan 2008 ## Contact & Social - LinkedIn: https://www.linkedin.com/in/bhushan-zambre-86830b3a --- Source: https://flows.cv/bhushanzambre JSON Resume: https://flows.cv/bhushanzambre/resume.json Last updated: 2026-04-07