Muhammad Ijlal
Mechanical/Product Design Engineer
About
Muhammad is a Mechanical Design Engineer with experience in designing and developing products across industries, including datacenters, automotive, consumer goods, and energy. He enjoys solving complex engineering challenges, focusing on efficiency, reliability, and user-centric design.
His work includes collaboration with cross-functional teams, hands-on prototyping, and continuous improvement to ensure quality and cost-effectiveness. He's passionate about learning and contributing to projects that create meaningful impact.
Experience in Numbers
Work Experience
Recommendations
Daniel Neumann
Former Co-worker on the same team
“Muhammad has a gift for picking up new and complex topics very quickly, which allowed him to hit the ground running and make a positive impact very quickly. I've been impressed with Muhammad's grasp of engineering fundamentals and his ability to apply them when solving problems."
Former Manager
Andrew Larson
"He's an effective communicator and is intrinsically motivated - a powerful combination in a technical engineer that led to high-output and a successful track record of simplifying complex ideas to achieve stakeholder alignment. "
Emery Frey
Former Co-worker on the same team
“He approaches complex problems with enthusiasm and has a keen ability to ask insightful questions that get to the heart of design challenges.”
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"With a strong foundation in engineering principles, Muhammad consistently applies his technical expertise to deliver effective solutions, and he is always eager to expand his knowledge whenever the opportunity arises."
Garrett Pauwels
Former Co-worker on the same team
“He is an extremely fast learner and ramped up very fast in such a short time driving success on projects immediately. He is data driven, personable and easy to work with. He is also an exceptional engineer! I highly recommend Muhammad!"
Featured Projects
Mechanical Design Engineer
June 2024 - November 2024
Muhammad's team led the design, development, and validation of mechanical components for the Datacenter CPU Loading Mechanism. This responsibility spanned the entire product lifecycle, from initial concept development, through detailed engineering design and rigorous testing, to manufacturing readiness.
Socket Covers
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Led design, analysis, and validation testing of an injection-molded socket cover, engineered to protect high-value motherboards (>$1,000 each), mitigating $20M/year in potential damages.
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Requirements included performance in shock, vibration, temp/humidity cycling, durability, and deformation risks.
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Collaborated with offshore suppliers to optimize Design for Manufacturing (DFM), oversee First Article Inspection (FAI) and Production Part Approval Process (PPAP), and ensure tight tolerance control for high-volume production exceeding 10 million units.
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Improved installation torque of the socket cover by 35% through corrective analysis leveraging hand calculations, Finite Element Analysis (FEA), and experimental validation, with iterative rapid prototyping, while balancing shock and vibration performance and making critical design trade-offs decisions.
Next-gen Loading Mechanism Technology
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Led development and evaluation of the next-generation Datacenter Xeon CPU loading mechanism, facilitating the down-selection of the Plan of Record (POR) design.
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Defined and implemented robust testing procedures, reducing testing time by 50%, using Design of Experiments (DOE) methodology, developed supporting collateral, and managed data collection activities to ensure comprehensive analysis.
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Leveraged data insights to identify design trade-offs and proposed corrective actions to supplier technical leads, driving advancements in critical design features.
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Delivered in-depth technical and business analyses to internal cross-disciplinary teams and provided high-level executive summaries for program director decision ratification.
Customer Engagement for Design Improvement
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Spearheaded root cause analysis to address design challenges informed by customer feedback, identifying key areas for improvement and driving resolution.
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Conducted statistical tolerance analysis and employed iterative prototyping and testing, collaborating closely with external suppliers and internal cross-disciplinary teams to align on corrective actions with stakeholders.
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Delivered a streamlined solution that minimized production disruptions and reduced the need for extensive revalidation testing, achieving cost savings of over $300K while maintaining project timelines.
Battery Cell Mechanical Design Engineering Intern
January 2023 - August 2023
Muhammad's team at Tesla led the initial design and development of the mechanical components for Tesla's 4680 battery cell. The cell design emphasized safety during catastrophic events, seamless integration into automated high-speed assembly processes, maximization of energy density per cell, and achieving six-sigma yield in high-speed production by addressing and resolving design challenges from earlier cell generations.
During his tenure at Tesla, Muhammad contributed to the development of battery cells utilized in the Model Y, Model 3, Cybertruck, and other upcoming Tesla vehicles, ensuring the integration of cutting-edge technology across Tesla's product portfolio.
Ultra-Sonic Weld Fundamentals Study and Guide Development for Future Product
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Designed and executed experiments to investigate the fundamentals of the high-volume ultrasonic welding production process, leveraging engineering first principles for a data-driven approach.
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Study included setting up Design of Experiments (DOE), alongside designing cost-effective fixtures and custom dummy probes, saving $100K in testing collateral expenses and reducing study time by 40%.
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Generated valuable insights into production challenges associated with an upcoming vehicle's battery cell, informing design and manufacturing strategies.
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Produced a comprehensive guide detailing the capabilities and limitations of the ultrasonic welding process, serving as a key resource for future battery cell designs and production planning.
Redesign of Battery Cell Outer Shell
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Led the redesign of the battery cell's outer shell to enhance production yield and thermal performance by reducing deflection during manufacturing.
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Employed Finite Element Analysis (FEA), testing, iterative prototyping, tolerance analysis, and low-volume stamping tool design to create in-house mockups for design validation.
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Evaluated 29 unique rib designs and down-selected the optimal solution, achieving a 30% reduction in battery cell surface deflection.
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Surpassed performance requirements by 50%, delivering a robust and manufacturable design for high-volume production.
Validation Testing of Next-Generation Battery Cell Mechanical Component
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Led validation testing of mechanical components for a next-generation battery cell designed for an upcoming vehicle.
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Designed specialized test fixtures, formulated comprehensive trial plans using Design of Experiments (DOE), and conducted hermetic seal evaluations, including nitrogen and helium leak testing, to ensure component reliability.
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Developed multiple vision-based laser weld programs for in-house validation testing to replicate automated high-speed assembly lines.
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Leveraged data-driven analysis to recommend critical design modifications, addressing potential production challenges and ensuring readiness for mass production.
Design of Fixtures and Processes for Ultra-Sonic Weld Strength Testing
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Conceptualized and designed innovative fixtures and testing processes specifically focused on evaluating the strength of ultrasonic weld joints in both manufacturing and lab environments.
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Introduced new approaches that deviated from previous practices, enabling precise quantification of weld strength and enhancing the reliability of testing methodologies.
Failure Analysis of Runaway Battery Cells
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Conducted comprehensive failure analysis on destructively tested runaway battery cells to determine root causes of failure.
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Performed in-depth investigations to identify the initiation point of failure, assess the resulting conditions of each component post-test, and evaluate additional potential failure points to inform design improvements
Mechanical Design Engineering Co-op
May 2022 - December 2022
Muhammad was part of the Air Products team at Pregis that designed and developed machinery for inflating and sealing packaging pillows. From concept through to manufacturing, the team developed a solution that allowed packaging cushions to be inflated and sealed on-demand in seconds, as opposed to pre-inflating and storing them, thereby optimizing space in customers' warehouses. This innovative approach provided significant value to major clients, including McMaster-Carr, Walmart, Amazon, and Crate & Barrel, among many others.
Root Cause Investigation and Redesign of Heater Components
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Led the root cause investigation of machine failures during field testing and subsequently redesigned the heater components to resolve these issues.
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The investigation and redesign process included hand calculations, Finite Element Analysis (FEA), material research, iterative prototyping, testing, data analysis, and close collaboration with suppliers.
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The root cause analysis identified thermal expansion of the heater components as the primary factor behind the machine failures.
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The redesign of the heater components resulted in a 90% reduction in thermal expansion, eliminating machine failures (previously at 70%) and achieving a zero-failure rate due to heating assembly. Additionally, the material and mechanical design changes led to a 40% reduction in production costs.
BEFORE
AFTER
Continuous Improvement Projects
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Contributed to product performance improvement cycles, achieving a 75% reduction in product startup time while simultaneously reducing cost, complexity, and Bill of Materials (BOM) quantity.
Validation Testing
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Designed and implemented efficient, modular, and repeatable validation tests using custom test equipment, resulting in material savings of approximately $15K.
Additional Responsibilities
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Conducted root cause analysis for mechanical issues, identifying and addressing underlying factors.
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Supported field and lifecycle testing to ensure product reliability and performance.
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Designed and released detailed 2D manufacturing, inspection, and assembly drawings, ensuring clear communication and quality control.
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Developed comprehensive assembly guides to streamline production processes and maintain consistency.
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Assisted the production team in troubleshooting and resolving issues as they arose.
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Authored user manuals for customers and maintenance guides for the technical support team, ensuring proper operation and service procedures.
Mechanical Engineering Intern
May 2021 - August 2021
At Visual Comfort & Co., Muhammad’s team led the design and development of high-end lighting products, overseeing the process from initial concept to manufacturing. These products included lamps, chandeliers, channel lights for both indoor and outdoor use, and a variety of other lighting solutions for consumer and commercial markets. Each design focused on simplicity, aesthetics, and ease of use, ensuring that the final products met the highest standards of style and functionality.
Design and Development of Magnetic Mount
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Led the design and development of magnetic mounts, taking the product from initial concept through to manufacturing.
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The development process involved iterative prototyping, validation testing for functionality and code compliance, tolerance stack-up analysis, and the application of Design for Manufacturability (DFM) and Design for Assembly (DFA) principles.
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In addition to functional and code compliance, the product design prioritized user ease, ensuring tool-free operation through an interference fit.
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Selected spring-steel material for its ability to easily disengage without the need for tools, enhancing usability.
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Expanded the concept to design similar magnetic mounts for other products within the same portfolio.
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Magnetic mounts are currently being produced at a combined rate of 30,000 units per year, demonstrating successful high-volume scalability.
Additional Responsibilities
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Managed SolidWorks’ Product Data Management (PDM) and documentation, ensuring accurate and up-to-date records throughout the product lifecycle.
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Created detailed 2D manufacturing and assembly drawings to support production and quality control.
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Collaborated closely with manufacturing and industrial engineering teams to streamline production processes and optimize design for manufacturability.
Mechanical Engineering Intern
October 2021 - April 2022
Muhammad was a key member of the Nuclear Division at Hydro, where the team focused on the reengineering and design changes of cooling pumps critical to nuclear plant operations. Their responsibilities included reverse engineering replacement parts, implementing design changes to enhance performance, managing procurement processes, and collaborating closely with the in-house manufacturing team to ensure seamless production and delivery.
Responsibilities
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Authored comprehensive design reports, technical equivalency evaluations, and manufacturing plans, ensuring clarity and alignment across stakeholders.
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Redesigned critical pump components to enhance performance and reliability while adhering to project specifications.
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Collaborated with cross-functional teams on procurement processes and ensured compliance with ASME Code requirements, supporting seamless integration into manufacturing workflows.
Education
Master of Engineering
Mechanical and Aerospace Engineering
GPA: 3.8/4.0
Bachelor of Science
Mechanical Engineering
GPA: 3.6/4.0
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