Ashutosh Kale
@ashutoshkale
Simulation Engineer intern at BMW AG analyzing lithium-ion battery thermal runaway and heat propagation with STAR-CCM+.
GermanyWhat I'm looking for
At BMW AG, I conduct thermal safety simulations of lithium-ion cells and cell stacks to analyze thermal runaway, heat propagation, and propagation-stop concepts. I also develop parameterized CATIA V5 models and carry out CFD workflows from geometry preparation through post-processing.
At Volkswagen AG, I conducted thermal runaway tests on cells and cell stacks for battery safety validation and test development. I analyzed CT scans and electrical, mechanical, and thermal measurements to assess degradation, aging, and reusability, and supported CFD-based model validation in STAR-CCM+.
For my publication, “Trajectory Analysis of Ejected Particles during Thermal Runaway of Lithium-Ion Cells,” I developed a Python image-processing pipeline for automated particle tracking and physics-based models to investigate particle motion.
On a parallel mild-hybrid electric vehicle project, I led model-based development of a battery control strategy that achieved a 27% reduction in fuel consumption. I implemented strategies including start-stop, load-point shifting, and regenerative braking, then optimized the system using MATLAB/Simulink.
Experience
Work history, roles, and key accomplishments
Conducted thermal safety simulations of lithium-ion cells and cell stacks in STAR-CCM+ to analyze thermal runaway and heat propagation. Developed parameterized CATIA V5 models and performed complete CFD simulation workflows.
Conducted thermal runaway tests on lithium-ion cells and cell stacks for battery safety validation. Performed CT-scan analyses and analyzed measurement data to evaluate cell behavior and aging effects.
Intern - Race Engineer
Prudent Motorsports
Dec 2021 - Feb 2022 (2 months)
Conducted vehicle measurements and technical tests to diagnose thermal-management issues. Analyzed telemetry data using Race Studio and applied statistical analysis to optimize tire wear and performance.
Education
Degrees, certifications, and relevant coursework
TU Kaiserslautern
Master of Science, Commercial Vehicle Technology
2022 -
Grade: 1.9
Pursuing an MSc in Commercial Vehicle Technology with a focus on electric and hybrid vehicles, control theory, and vehicle propulsion systems.
MathWorks
Certification, Battery Pack Modelling
2026 - 2026
Completed the Battery Pack Modelling certification from MathWorks in January 2026.
Vector Informatik
Certification, AUTOSAR Architecture
2025 - 2025
Completed the AUTOSAR Architecture training at the CEA Summer School with Vector Informatik in September 2025.
MathWorks
Certification, Control Design Onramp with Simulink
2023 - 2023
Completed the Control Design Onramp with Simulink certification from MathWorks in May 2023.
Coursera
Certification, Sports and Building Aerodynamics
2020 - 2020
Completed the Sports and Building Aerodynamics course on Coursera in July 2020.
Savitribai Phule Pune University
Bachelor of Engineering, Maschinenbau
2017 - 2021
Grade: 1.9
Completed a Bachelor of Engineering in Maschinenbau (Mechanical Engineering) with a grade of 1.9.
Tech stack
Software and tools used professionally
Availability
Location
GermanyAuthorized to work in
Salary expectations
Social media
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