Swithin Ghils
Verified Expert in Engineering
Mechanical Design Engineer and Developer
Berlin, Germany
Toptal member since October 14, 2025
Swithin is a mechanical design engineer with 8+ years of experience in automotive and product design. An expert in plastic part design, tail lamps, and interior trims using CATIA V5, 3ds Max, and Teamcenter, he has led OEM-certified projects for Volkswagen, Škoda, Ford, Porsche, and Renault. Swithin has created CATIA automation macros, saving 300+ hours yearly. Skilled in DFMEA, DFM, prototyping, and additive manufacturing, he has contributed to algae-integrated urban design projects in Berlin.
Portfolio
Experience
- Design for Manufacture & Assembly (DFMA) - 9 years
- CAD - 9 years
- CATIA - 8 years
- Product Design - 8 years
- Injection Tooling - 7 years
- Product Lifecycle Management (PLM) - 6 years
- Plastics - 6 years
- Automotive Lighting Design - 4 years
Preferred Environment
CATIA, 3ds Max, AutoCAD
The most amazing...
...things I've delivered are the SK216 tail lamp from concept to launch with 100% approval and OEM-certified lighting designs for Volkswagen and Škoda.
Work Experience
Mechanical Engineer | Working Student
Solaga UG
- Created CAD drawings for prototypes at Solaga, ensuring functional and aesthetic standards.
- Supported material procurement and testing processes for product development.
- Presented design updates and addressed challenges during weekly meetings.
Application Engineer | Assistant Manager
Varroc Lighting Systems
- Led the technical aspects of the VW/SK MQB2.0 India and Russia tail lamp programs, overseeing feasibility analysis through to testing.
- Represented Varroc in Russia as a technical expert for the VW316 tail lamp program, ensuring design acceptance and improvements.
- Collaborated with OEMs and cross-functional teams for the successful delivery of VW-Škoda India and Russia tail lamp projects.
- Conducted workshops and method training in CATIA V5, DFMEA, and EnterProj for internal teams.
- Led Škoda Kushaq and VW Virtus tail lamp projects, managing design, 3D modeling, and engineering releases using CATIA V5.
- Conducted thermal, vibration, and optical simulations to ensure design specifications were met.
- Integrated electrical PCBs, connectors, and thermal management systems with optimized space utilization.
- Collaborated with OEMs and Tier 1 suppliers to ensure seamless vehicle integration.
- Completed 100% of BMG testing tasks ahead of schedule.
- Collaborated effectively with cross-functional teams from concept through to development.
Design Engineer
Faurecia Interior Systems
- Contributed to the Renault ZOE 2.0 Interior Trim‑IP project by creating CAD models, adapting styling surfaces, and conducting packaging studies.
- Developed proficiency in CATIA V5 and PLM systems like Teamcenter.
- Collaborated with the CAD team at Faurecia in Pune, Maharashtra, India, to ensure successful project completion.
Design Engineer
Pioneer Design & Engineering Pvt
- Managed CAD models for automotive body interior and exterior lighting at Faurecia Interior Systems and Varroc Lighting Systems.
- Utilized CATIA V5 and PLM systems like Teamcenter for concept creation, 3D modeling, and engineering releases.
- Developed proficiency in CATIA V5 and PLM systems like Teamcenter.
3D Print Artist
iClone, Bahrain
- Developed 3D printable models and miniatures using 3ds Max for iClone Bahrain.
- Managed preparation, planning, cost estimation, and inspection of the printing process.
- Achieved high-quality prints and optimized production efficiency through meticulous attention to detail.
CAD Operator
Kochi Metro Rail Ltd (Freelance Client)
- Developed 3D models of a metro station using 3ds Max 2013 for visualization purposes.
- Created structural drawings and road diversion plans using AutoCAD 2013.
- Estimated the volume of precast structures to enhance project planning efficiency.
CAD Engineer
UIT Group International
- Provided AutoCAD and 3ds Max training to students for interior and exterior design projects.
- Guided students in developing design skills and creating innovative design solutions.
- Collaborated with students to bring their design visions to life, fostering creativity and technical proficiency.
Experience
Škoda Kushaq Tail Lamp Design and Development
https://www.skoda-storyboard.com/en/kushaq_light_rear03/Additionally, I collaborated with OEMs and Tier 1 suppliers to ensure seamless integration of vehicles. We achieved 100% completion of BMG testing tasks ahead of schedule.
VW Virtus Tail Lamp Pre-development
https://volkswagenjodhpur.com/assets/images/modelpage/virtus/safety/volkswagen-virtus-taillamps.jpgMahindra XUV 500 Headlamp Facelift Project
https://imgd.aeplcdn.com/1056x594/n/cw/ec/34024/xuv500-exterior-daytime-running-lamp-(drl).jpeg?q=75&wm=1Education
Master of Science Degree in Project Management
Arden University - Berlin, Germany
Bachelor of Technology Degree in Mechanical Engineering
Mahatma Gandhi University - Kottayam, Kerala, India
Skills
Tools
CATIA, 3ds Max, CAD, AutoCAD
Industry Expertise
Project Management
Languages
C
Paradigms
Agile, Agile Project Management, Mechanics of Materials
Other
Project Analysis, Leadership, Production Engineering, Design for Manufacture & Assembly (DFMA), Prototyping, Teamcenter, Automotive Lighting Design, Product Design, Plastics, Injection Tooling, Product Lifecycle Management (PLM), Supply Chain Management (SCM), Project Management & Work Tracking Tools, Production Planning & Control (PPC), Machine Design, IT Project Management, Total Quality Management (TQM), Industrial Engineering, Instrumentation, Mathematics, Mechatronics, Hydraulic Engineering, Electrical Engineering, Electronics, Fluid Mechanics, Metallurgy, Materials Science, Thermodynamics, Enterproj, Design Failure Mode and Effects Analysis (DFMEA), Lean Project Management, Technical Documentation, Design For Assembly (DFA), Product Data Management (PDM), Automotive Plastic Trim Design, Engineering, 3D Printing, Planning, Cost Analysis, 3D Modeling, 3D Interior Design, Exterior 3D Modeling, Product Development, Lighting, Exterior Design
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