There is an ever-increasing focus on designing and developing Automotive Mechanical components and systems that meet stringent performance, safety, and sustainability standards.  

Vasanth Kumar, our next pathbreaker, Design Engineer at Volvo Cars (Sweden), translates functional requirements into robust, manufacturable designs.

Vasanth talks to Shyam Krishnamurthy from The Interview Portal about how his early exposure to real, hands-on Automotive Manufacturing and Fabrication projects propelled his career in Mechanical Design.

For students, embrace mistakes — they teach lessons no textbook can. Ask questions freely — curiosity fuels growth, so keep your inquisitive spark alive. 

Vasanth, can you share your background with our young readers? 

I grew up in Chennai, Tamilnadu with a childhood curiosity about unpacking things in order to understand how they worked, often dismantling small gadgets to understand their working mechanisms. My first experiment was on a bicycle bell that I took apart when I was in grade 5 and from then on the experiments became bigger and more expensive (like my RC car which I didn’t manage to assemble again, RIP Rambo the RC). 

What did you do for graduation/ post-graduation? 

This attraction led me to the study of engineering. I did my Bachelor’s in Mechanical Engineering at Anna University, which gave me a solid foundation in core engineering fundamentals. 

I had the privilege of captaining my team in the Baja SAE India ATV Championship held at Natrax, Pithampur. Leading a multidisciplinary group of engineers, I oversaw the end-to-end design, fabrication, and testing of our all-terrain vehicle. The experience sharpened my leadership and problem-solving skills, while giving me first-hand exposure to high pressure engineering challenges and competitive motor-sport environments. This time I was able to assemble the mechanisms that I had dismantled unlike in grade 5. Thinking about it, who would say ‘no’ to building a buggy with 25 other inquisitive engineering minds, which also doubled down as my bachelor’s thesis. 

Post-graduation, I felt an urge to explore how engineering felt and looked across the sea. In order to experience my Scandinavian Dream, I went to Chalmers University of Technology in Sweden to do my Master’s in Product Development specializing in product design processes, user-centered development, and innovation.Throughout my Master’s journey I worked on several industry-based projects related to user-centric design, sustainable solutions, and cross-disciplinary teamwork. It was here that I continued my motorsport passion by joining the Chalmers Formula Student Driverless team. The racing season was cut short by COVID and unfortunately, we never saw our car make it out on track. However, very fond memories come to mind whenever I ponder over this racing event. 

What were some of the key influences that led you to such an offbeat, unconventional, and unique career in Automotive Engineering? 

From a young age, I was fascinated by how machines worked — I would often dismantle and reassemble everyday gadgets just to understand the mechanisms inside. This natural curiosity was one of the earliest drivers that steered me towards mechanical engineering. 

My inspiration to become an engineer also comes from my father who was a quality control engineer at Ashok Leyland during his 30’s. It used to be fun listening to many challenges that arose during his time and how he tackled them to the finish line. Many of his moments from work instilled in me the discipline and inquisitiveness that still motivate me today. 

My academic environment at Anna University played a huge role. During my bachelor’s, a few professors and project guides encouraged me to take ownership of complex design challenges. Their guidance during Baja SAE, in particular, gave me the confidence to lead and innovate as it exposed me to real-world engineering challenges and competitive events like Baja SAE India. The blend of theory and hands-on problem-solving solidified my interest in designing functional, high performance systems. 

Captaining my team at the Baja SAE India ATV Championship at Natrax Pithampur was a turning point. The experience of leading the design, build, and testing of an ATV under strict timelines mirrored real world product development and made me realize I wanted to pursue this as a career. 

Moving to Sweden for my Master’s in Product Development at Chalmers was another defining moment. At Chalmers, I also had industry mentors who helped me see how product development could be both creative and technical. 

Working on industry projects there showed me the impact of combining engineering precision with user-centric design — a balance that I now strive for in my role at Volvo Cars. 

How did you plan the steps to get into the career you wanted? Tell us about your career path 

From early in my bachelor’s degree at Anna University, I had a clear vision of wanting to work in mechanical design and product development. My approach was to build a combination of strong technical fundamentals, practical project experience and global exposure to industry practices. 

I believed that to excel in mechanical design, I needed both theoretical depth and hands-on experience on application driven projects. That’s why I sought out projects like the Baja SAE India ATV Championship, where I could apply classroom learning to real engineering challenges. I also planned my academic path so that my bachelor’s would give me broad mechanical engineering knowledge, and my master’s would specialize in product development, bridging engineering and design innovation. 

During my undergraduate years, I took internships that gave me exposure to manufacturing processes, CAD design, and component testing. These were at Rane, Tafe and Ashok Leyland respectively. These experiences helped me understand the industrial context of mechanical design. 

During my masters at Chalmers, I worked on collaborative projects with industry partners, focusing on developing concepts and prototypes in line with user needs and manufacturability. These projects strengthened my ability to work in cross-functional teams. Key projects amongst these were the projects involving energy efficiency in revolving doors at Assa Abloy and the Chalmers Formula Student Driverless project. 

As part of the Product Planning, “Needs and Opportunities” course in my Master’s program in Product Development, I collaborated with five peers on an industrial project titled “Minimising Air Leakage in Revolving Doors.” The project was supported by ASSA Abloy Entrance Systems and Chalmers University of Technology. 

Our team focused on developing an innovative sealing solution to reduce air leakage in revolving doors. I contributed during the pre-development phase, conducting product benchmarking and user observations. Additionally, I was one of three team members selected to present our preliminary findings to supervisors and fellow students. 

I also had an opportunity to work on Digital Twin and Electric Propulsion Systems – It was a graduate research project which I had to cut short due to my immediate joining at Volvo Cars.  

My master’s thesis was on reducing “Misconstraining in Automotive Assembly” in collaboration with Volvo Cars and Chalmers University of Technology, which was part of the AMIGO Project funded by Vinnova (Sweden’s Innovation Agency). Vinnova advocated the development of the first-ever mapping model addressing misconstraining issues in automotive assembly by evaluating 5+ real-world test cases. In automotive assembly, misconstraining refers to the improper positioning of parts during assembly, leading to potential issues in the final product. This can result in dimensional inaccuracies, increased rework, and quality problems.

I was involved in the following:

  • Investigated compliancy problems in 3+ car models and implemented a risk-reduction checklist to systematically minimise misconstraining during design and production. 
  • Hoverboard Wheel Assembly – Design & Development (Summer Project during CoVID) In collaboration with CAM² – Centre for Additive Manufacturing Metal, Chalmers University of Technology 
  • Designed and developed the wheel assembly of a hoverboard, later fabricated via 3D printing. The rim and tire components were created using generative design and topology optimization techniques to enhance performance and reduce material use. All parts were engineered following Design for Additive Manufacturing (DfAM) principles, with technical guidance from the CAM² research team. 
  • Designed and developed 10+ autonomous hardware mountings and conducted structural analysis of mechanical components related to the High Voltage (HV) system. 
  • Led 5+ studies on the cooling concept for the electrical system, resulting in a 10% improvement in cooling efficiency. 
  • Spearheaded the team during the Cost and Manufacturing Static Event at Formula Student Germany, driving strategy and documentation efforts. 
  • The season had to be cut short due to CoVID-19 and hence a lot of the on track performance versus design efficiency was not tested 

After my master’s, I joined Volvo Cars as a Mechanical Design Engineer.I currently work at Volvo, where I design components and systems that meet strict performance, safety, and sustainability standards, applying the blend of technical knowledge and design thinking I developed through my education and earlier experiences. 

How did you get your first break? 

My master’s thesis at Volvo Cars is connected to my current role. My thesis supervisor gave a recommendation to the then hiring manager in support of my application and that along with my formula student background and master’s degree helped me get my first career break. I am as of today continuing with the same role and will soon complete 4 years in this role. 

I also actively sought feedback on my skills, participated in design competitions conducted by SAE and ASME, and built a strong skillset in CAD and simulations. This continuous learning approach ensured I stayed relevant and adaptable as I progressed into my current career. 

Networking through university alumni, professors, and industry events helped me learn about opportunities and understand the skills valued in the industry. My connections from Chalmers and my project collaborations provided insights into the automotive sector in Sweden, which helped in securing my role at Volvo Cars. 

What were some of the challenges you faced? How did you address them? 

The biggest challenge I faced was the transition from academia to industry and the introduction of the product development system which was unique to Volvo Cars. There are steps and processes that weren’t made available in the curriculum while studying, and this made it essential to unlearn and re-learn a lot of concepts. 

Where do you work now? What problems do you solve? 

I currently work as a Mechanical Design Engineer at Volvo Cars, where I focus on designing and developing mechanical components and systems that meet stringent performance, safety, and sustainability standards. 

I work on translating functional requirements into robust, manufacturable designs. This often means solving challenges around space constraints, material selection, durability, cost-efficiency, and ensuring compliance with safety regulations. I also collaborate with cross functional teams to address integration issues between components, optimize designs for manufacturing, and troubleshoot any performance concerns that arise during testing. 

What skills are needed for the job? How did you acquire them? 

Key skills include 3D CAD modeling, design for manufacturability, knowledge of materials and mechanical systems, and problem-solving in cross-functional environments. I also rely on soft skills like communication and project management. 

What’s a typical day like? 

My day usually starts with team sync meetings (Daily Stand Up (DSU)) to align on project goals and priorities. I then spend time on CAD modeling, reviewing design requirements, and collaborating with manufacturing, testing, and quality teams to refine concepts. Some days involve design reviews, supplier discussions, or visiting test facilities to evaluate prototypes. It’s a good mix of desk work and interaction with different stakeholders. 

What is it you love about your work? 

I love the fact that I get to work on products that millions of people interact with daily — cars that are not only functional but also safe, comfortable, and sustainable. The job challenges me to think creatively while staying rooted in engineering reality. I also enjoy the collaborative culture at Volvo Cars, where diverse perspectives come together to solve complex problems. 

How does your work benefit society? 

We design parts with sustainability at the core wherein the type of material used and the consolidation of parts in a mechanism help reduce the carbon footprint of each of these designs. We also make sure that we introduce sustainability in our daily engineering practices like reducing the use of paper cups for tea/coffee and instead use porcelain mugs that can be reused. 

Tell us an example of a specific memorable work you did that is very close to you! 

One of the most memorable projects I’ve worked on — and one that’s very close to me — was my contribution to the head impact certification and rating process for the Volvo EX90, which is now in production in the USA. 

This was a high-stakes safety-critical project, as it directly related to occupant protection and compliance with strict regulatory standards. My role involved designing and refining interior components in areas subject to head impact tests, ensuring that materials, geometries, and mounting strategies met both legal requirements and Volvo’s own higher safety targets. 

I worked closely with simulation engineers to analyze impact energy absorption, iterated CAD models to optimize performance, and coordinated with testing teams to validate designs in physical trials. Every design change had to balance safety performance, manufacturing feasibility, and aesthetic integration with the vehicle’s interior. 

Seeing the EX90 roll into production — knowing that my work contributes to protecting lives in real-world scenarios — was deeply rewarding. It wasn’t just about meeting certification numbers; it was about upholding Volvo’s safety legacy and knowing I had a tangible hand in shaping that. 

Your advice to students based on your experience? 

Embrace mistakes — they teach lessons no textbook can. Ask questions freely — curiosity fuels growth, so keep your inquisitive spark alive. 

Be ready to unlearn and relearn — learning has no age limit. Don’t let impostor syndrome hold you back — it’s just background noise; focus on improving and moving forward. 

Future Plans? 

My short-term goal is to become a subject matter expert in pedestrian safety/occupant safety. In the long term, my vision is to become the CTO of an automotive OEM while continuing to inspire others along the way.