# Mohammad Kaif P.

> Product Design Engineer @ Koch | Mechanical Design & Systems Engineering | Georgia Tech MSAE

Location: San Francisco, California, United States
Profile: https://flows.cv/mohammadkaifp

Product Design Engineer with an MSAE from Georgia Tech and 3+ years of work experience in fast‑paced R&D, delivering production‑ready solutions at the intersection of systems, mechanical design, and software‑hardware integration in the automotive/Consumer electronics industry. I translate customer and safety requirements into elegant, testable designs, and I thrive in cross-functional environments focused on quality, cost, weight, and reliability.

Currently at Molex, Deep expertise in designing high-speed interconnects and precision electromechanical packaging for mass production (>10M units/year). I Currently bridge the gap between mechanical constraints and Manufacturing requirements, delivering robust hardware solutions for the automotive and consumer electronics markets. I specialize in the full product lifecycle—taking designs from initial concept and master modeling (Siemens NX) through rigorous validation (EVT/DVT/PVT) to high-volume manufacturing ramp.

Core Competencies: 🛠 Mechanical Design: Siemens NX (Advanced Surfacing), GD&T (ASME Y14.5), Tolerance Analysis (RSS/Worst-Case), DFM/DFA. 🔬 Analysis & Validation: Ansys (FEA), Structural/Thermal Simulation, IP67 Sealing, Root Cause Analysis (Fishbone/5-Why). 🏭 Manufacturing: High-Cavitation Injection Molding, Insert Molding, Stamping, Tooling Disposition (FAI/Cpk).

I thrive in cross-functional environments, partnering with reliability, electrical, and tooling teams to deliver high-yield, cost-effective hardware.

## Work Experience
### Product Design Engineer @ Koch
Jan 2024 – Present
Own the end-to-end mechanical design of high-speed connector systems and precision electromechanical packaging, scaling production to 10M+ units/year while maintaining critical Process Capability (Cpk > 1.33).

• High-Volume Design: Lead the master modeling (Siemens NX) and architectural layout of complex interconnects, managing 5,000+ mechanical interfaces and ensuring 100% fit assurance via rigorous Statistical Tolerance Analysis (RSS).

• Validation & Disposition: Manage EVT/DVT/PVT build phases, leading First Article Inspection (FAI) and tooling disposition reviews to authorize tool modifications and define "Limit Samples" for global production.

• Simulation-Driven Design: Utilize Ansys for structural and thermal FEA to validate snap-fits, housing deformation, and retention features under automotive vibration/thermal loads, reducing prototype iterations by 30%.

• Cross-Functional Optimization: Partner with Signal Integrity teams to optimize terminal geometry for high-speed performance (10Gbps+) while driving DFM improvements with Asia/Europe molders to reduce cycle time by 12%.

• Reliability & Sealing: Developed IP67-rated sealed enclosures utilizing LSR gaskets and adhesives, executing DFMEA (3,000+ modes) to align designs with USCAR/GMW validation standards.

### Research Associate @ Aerospace Systems Design Laboratory (ASDL)
Jan 2023 – Jan 2024 | Atlanta, Georgia, United States
𝗙𝗔𝗔 𝗔𝘀𝗰𝗲𝗻𝘁 𝟴𝟮 𝗔: 𝗗𝘂𝗮𝗹 𝗡𝗼𝗶𝘀𝗲 𝗮𝗻𝗱 𝗘𝗺𝗶𝘀𝘀𝗶𝗼𝗻 𝗦𝘁𝗿𝗶𝗻𝗴𝗲𝗻𝗰𝘆 𝗔𝗻𝗮𝗹𝘆𝘀𝗶𝘀:

Goal: Provide Technical Assitance to FAA in policy making for future Noise and Aircraft Emission using a data-driven decision-making Process.

1) System Architecture Design, Testing and Validation:
•	Developed 95% accurate M&S systems architectural capability to assist FAA in policy making by providing technical support using a data-driven decision-making process using Design of experiments, surrogates- neural nets on JMP, MATLAB.
•	Led multidisciplinary teams in managing initial sponsors requirements, translate sponsor needs into safe deployable requirements. Analyzed, decomposed, verified - validated and then optimized functional predictive systems models for 99% match to real life aircraft. 
•	Conducted statistical analysis to study key metrics against design variables for verification-validation using FLOPS, NPSS, ALCAA and JMP to recommend future investments that fulfill regulations by infusing future technologies provided by GE, Boeing, Honeywell, and Pratt & Whitney.

### Research Assistant @ Aerospace Systems Design Laboratory (ASDL)
Jan 2022 – Jan 2023 | Atlanta, Georgia, United States
𝗡𝗔𝗦𝗔 : 𝗔𝗱𝘃𝗮𝗻𝗰𝗲𝗱 𝗥𝗲𝗴𝗶𝗼𝗻𝗮𝗹 𝗔𝗶𝗿 𝗠𝗼𝗯𝗶𝗹𝗶𝘁𝘆 𝗦𝘁𝘂𝗱𝘆
Goal: Facilitate a cost-effective and safe Regional Air transportation network by Electrifying Regional Jets and convert under-utilized secondary airports in the USA to facilitate this operation.

● Crew-Pair Modelling: The objective is to optimize the aircraft network for specified routes, maximizing profit while minimizing downtime, and optimizing flight hours for both crew and pilots.

Developed and fine-tuned a crew pair model for approximately 10,000 routes within the Northeast Corridor, integrating FAA Part 23, 91, 121, and 135 regulations. Utilized Python with the Gurobi optimizer to significantly decrease airline network operating costs by 65% and eliminate pair redundancy entirely.

● Modeling Airport Microgrids - Employing PV Watts to support the development of charging infrastructure at airports and calculate electricity production from solar panel installations.

● Led aircraft and engine calibration and sizing initiatives for 2, 4, 9, 16, 30, and 48 passenger aircraft. Contributed to the implementation of a battery model to electrify cruise and descent phases of the aircraft mission, resulting in a 35% reduction in fuel costs and optimizing a predictive model with 1000% improved accuracy.

### FEA Developer @ Hexagon Manufacturing Intelligence
Jan 2023 – Jan 2023 | Irvine, California, United States

### Mechanical Design Engineer @ Space Technology and Aeronautical Rocketry
Jan 2021 – Jan 2021 | Surat, Gujarat, India

### Mechanical Engineer @ Bangalore Aircraft Industries Pvt. Ltd.
Jan 2021 – Jan 2021 | Bengaluru, Karnataka, India

### Hybird and Electric Vehicle design Intern @ Verzeo
Jan 2021 – Jan 2021 | Bengaluru, Karnataka, India


## Education
### Master of Science - MS in Aerospace, Aeronautical and Astronautical Engineering
Georgia Institute of Technology

### Bachelor of Technology - BTech in Aerospace, Aeronautical and Astronautical Engineering
SRM IST Chennai


## Contact & Social
- LinkedIn: https://linkedin.com/in/kaif-pathan

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Source: https://flows.cv/mohammadkaifp
JSON Resume: https://flows.cv/mohammadkaifp/resume.json
Last updated: 2026-03-29