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The automotive industry is in the middle of a fundamental shift toward cleaner, more efficient products and practices. For example, eco-friendly manufacturing processes are changing how cars are built and operated, innovations in artificial intelligence are improving data analysis, and electric vehicles and hybrid powertrains are slowly dampening humanity’s carbon footprint.
Powering these advancements are engineers like Vikrant Rayate. With a background in mechanical engineering, Vikrant has focused his career on improving powertrain systems and conducting extensive research to find sustainable solutions for these complex infrastructures.
But beyond his engineering experience, Vikrant is also committed to mentoring the next generation of engineers, guiding young professionals in the workplace, and supporting students in hands-on projects. In conjunction with his practical work and scholarly research, he’s advancing both the technology behind modern vehicles and the future of the professionals who will continue this work.
Vikrant’s approach to engineering innovation
After graduating with a master’s degree in mechanical engineering from Clemson University, Vikrant Rayate has spent the last 12-plus years specializing in automotive product development. He’s worked for original equipment manufacturers (OEMs) such as Stellantis and automotive suppliers like KSPG Automotive, and he’s currently employed at ZYNP International Corp.
Over the course of his career, Vikrant has specialized in powertrain design and dedicated his career to making vehicles more efficient, durable, and environmentally friendly. This includes designing critical powertrain components — including pistons, piston pins & rings, and connecting rods — and contributing to improvements in NVH (noise, vibration, and harshness) metrics. He also has expertise in integrating technologies like electric and hybrid systems, as well as leading cross-functional teams to deliver innovative solutions.
His work has aligned with and furthered the industry’s increasing focus on smarter, more sustainable automotive systems. In doing so, he’s directly contributed to the growing prevalence of advanced technologies like electric vehicles, which are expected to represent 130 million units on the road by 2030.
This rapid, ongoing growth has pushed automaker manufacturers to lower emissions, reduce energy waste, and meet the increasing demand for more efficient and eco-friendly vehicles. Vikrant has been addressing these challenges directly, leading multiple large-scale projects to develop reliable engines that bring value to businesses and consumers alike.
“I know firsthand how strategic engineering decisions can directly impact business outcomes,” he says. “That’s why I’m committed to combining technical skills with practical solutions.”
Contributing to automotive research
In conjunction with these practical innovations, Vikrant has also authored several scholarly articles over the years. His findings have been featured in many renowned industry journals, and they’ve addressed key issues in powertrain development, like improving engine performance, reducing oil consumption, and advancing sustainable solutions.
Root cause analysis of high oil consumption in 6.4L heavy-duty engines under urban driving conditions
While working as a powertrain design release engineer at Stellantis, Vikrant led a major study focused on reducing urban oil consumption in heavy-duty engines, which were achieving 5,000–6,000 miles per quart (MPQ) — far below the 26,000 MPQ benchmark set by competitors.
Using a DFSS (Design for Six Sigma), Vikrant and his team tested various engine structure modifications, such as altering the top ring shape, increasing second-ring tension, and adjusting the oil rail face. In doing so, he effectively reduced oil consumption by 50%.
These findings were later published in the Power System Technology Journal.
Rod and pin optimization on 6.4L heavy duty engine for bushing wear and noise reduction
A similar study that Vikrant led focused on finding practical solutions for what’s known as the “pin tick” problem, which is caused by excessive wear on the engine rod bushing and leads to multiple issues with performance. Previous improvements, such as introducing roundness specifications for the pin bore, proved to be insufficient to completely solve the problem, and Vikrant was tasked with developing a new solution.
In this scenario, Vikrant conducted several root cause analyses and tests in noise, vibration, and hardness, eventually tracing the root cause to poor lubrication mechanisms. After testing a new bushing design, he and his team were able to reduce wear and extend engine life, resulting in $0.7 million in savings.
Oil consumption optimization for heavy duty engine using design for six sigma
Vikrant also investigated unexpected oil losses during Multiple Displacement System (MDS) events, which occur when an engine temporarily shuts off its cylinders to save fuel.
His research used simulation software to test how oil moved through the engine and evaluate different piston ring designs to reduce consumption — a process that would effectively minimize waste without compromising the engine’s performance.
Advancing the industry alongside peers
In addition to his own research, Vikrant acts as a peer reviewer for journals like Mechanics of Advanced Materials and Structures, the Journal of Artificial Intelligence Research, and the Journal of Science & Technology, evaluating new studies to ensure they meet scientific standards and contribute meaningful advancements. His editorial board positions allow him to shape the direction of automotive engineering research, ensuring a focus on impactful and innovative studies.
He also recently served as a judge for the SMASIS Best Student Paper Award, where he assessed research submissions from emerging engineers and selected finalists and winners.
Throughout these initiatives, Vikrant seeks to leverage the power of research to uncover and promote more efficient approaches to existing systems. As he puts it, “Sometimes, innovation is less about inventing something new and more about seeing familiar things in a new way.”
Mentoring the next generation of engineers
While advancing technology is crucial, Vikrant believes that shaping the next generation of engineers is just as important. That’s why he’s dedicated much of his career to mentoring aspiring engineers, helping them hone their technical skills. He would also emphasize the ability to navigate complex challenges, teaching his mentees how to break down a complicated process into smaller, more manageable pieces. “I always tell my team, ‘Let’s solve one part really well and build from there,’” he says. “This approach not only delivers results but helps build confidence in one’s ability along the way.”
His mentorship includes coaching in product lifecycle management and methodologies like Six Sigma, which helps them set clear project goals and analyze data to implement effective solutions, and Lean Manufacturing, which teaches them how to eliminate inefficiencies in workflows.
Vikrant also mentors engineering students through multiple academic programs. Recently, he served as an industry advisor for Clemson University’s team in Stellantis’ Battery Workforce Challenge, a competition focused on designing energy storage solutions for electric vehicles. In this role, Vikrant guided the university’s team in creating a battery cooling system to prevent overheating, helping them refine their approach and ensuring they stayed on track with their timelines. Under his mentorship, the project earned several awards, including Best Cell Characterization, Best Cell Characterization Analysis Report, and Best Final Project Management.
For Vikrant, mentoring goes beyond providing technical advice — it’s about nurturing the mindset that engineers need to creatively approach challenges. “I often tell my mentees, ‘Engineering isn’t just about solving problems; it’s about learning to love the process of figuring them out,’” he explains. “So it’s incredibly gratifying to see them develop that mindset and apply it to create real-world solutions.”
A holistic view on engineering
To Vikrant, research and mentorship are two very intertwined aspects of his career. His research informs his approach to mentorship, as he shows young engineers how his methods work in real-world scenarios while providing them with access to the latest advancements in automotive technology. The result is a multifaceted approach to the long-term development of the industry, setting him apart from his peers.
Vikrant believes both aspects of his work are critical, especially as the industry moves toward more sustainable solutions that will require the development of more complex systems. “By sharing my expertise and encouraging a mindset of continuous improvement and refinement,” he explains, “I hope to make a lasting impact that shapes both the automotive industry’s progress toward sustainability and the careers of the engineers who will lead it forward.”
Shaping the future of the automotive industry
Vikrant Rayate’s career is a powerful example of how research and mentorship can go hand-in-hand to make a lasting impact in the automotive industry.
By devising practical solutions that advance the field of engineering while equipping aspiring engineers and ensuring the future of the industry, Vikrant is taking significant steps in realizing the vision of a more efficient and sustainable automotive landscape.
