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EV Chargers and Connectors
Project type
Industrial
Date
August 2018 - March 2020
Location
Aptiv Connection Systems, Chennai. India
Description
At Aptiv, I designed automotive and EV charging connector systems rated up to 400–800 V, ensuring compliance with creepage/clearance standards and thermal limits under high-current operation. Performed thermal load assessments and supported validation under vibration (>20 g), temperature cycling (-40 °C to 125 °C), and IP-rated sealing conditions. Led tolerance stack-up and DFM studies, reducing tooling revisions by ~15%. Collaborated with validation teams to resolve failure modes identified during environmental and durability testing. Delivered production-ready designs supporting high-volume automotive manufacturing.
