Concept to
production.
One team of record.

Form Engineering Solutions was founded to help more teams bring ambitious vehicle and hardware concepts to reality — end-to-end development, from first architecture sketch to production readiness.

Start a conversation  →
EV · Mobility · Hardware · Climate-Techformengg.com

Hardware programs live or die on a handful of decisions — what to build, how to make it, who makes it, and when it's ready. Form Engineering owns those decisions across product development, program management, supplier search, and production readiness, so early-stage teams get them right the first time.

Capabilities

End-to-end. Not end-to-handoff.

01 — Product Development & Engineering

Vehicle Architecture & Packaging

Architecture definition & feasibility · full-vehicle packaging · frame & body structures · L7 / quadricycle-category vehicles · industrial design integration

Interiors, Exteriors & Seating

Interior systems · seating structures & mechanisms · trim & closures · exterior panels & surfacing support · CMF direction

Ergonomics & Occupant Packaging

H-point analysis · occupant package studies · HMI feasibility · ingress / egress · vision & reach studies

Analysis & Validation

FEA-driven structural design · DFMEA / DVP&R · mass optimisation · composite architectures · GD&T & tolerance strategy

02 — Program & Project Management

Technical Program Management

Program planning & execution · risk management & mitigation · budgeting & resource allocation · PLM & BOM management · stakeholder communication across international teams

Embedded Technical Leadership

Senior lead of record on contract programs · CAD support & studio engineering — NX, CATIA V5/V6, SolidWorks, OnShape, Rhino · cross-functional and supplier team leadership

03 — Supplier Search & Manufacturing

Supplier Discovery & Coordination

Supplier search, technical evaluation & selection · RFQ management · coordination across China, India, US, Mexico & Germany · quality & launch support

Manufacturing Strategy

Manufacturing method selection — injection moulding, extrusions, stamping, die casting, thermo-vacuum forming, composites, honeycomb panels · DFM / DFA · make-vs-buy · cost modelling · tooling strategy

04 — Production Readiness & Launch

Prototyping & Physical Validation

Package bucks · functional mockups · rapid prototyping & additive · low-volume builds · seating & interior rigs

Readiness, Compliance & Launch

Production readiness roadmaps · validation testing & regulatory compliance · homologation documentation · line-side troubleshooting & root-cause analysis · supplier fit / finish resolution through builds

Programs

Vehicles shipped. Outcomes on record.

Pebble Mobility2024–25 Engineering Lead, Interior Systems — electric RV Production interiors launched ahead of schedule · 60% supplier cost reduction across five countries · 40%+ FEA-driven weight reduction · 50+ specifications owned
Arrival2021–24 Engineering Lead, Interior Systems — US transit EV vans & buses New interior architecture for the Delivery Van · cargo shelving mass −50%, cost −60% · cross-system integration across seven domains
Exponent2020–21 Sr. Automotive Consultant — Honda & Toyota, vehicle safety Interior & seat crash-performance analysis · event data recorder imaging and analysis for OEM safety evaluations
Canoo2018–20 Sr. Mechanical Engineer — interior & seating systems Rear quarter panels −15.6% mass via composites · Package Buck program delivered with 26% cost saving · driver-seat health-sensor integration
Faraday Future2015–18 Sr. Mechanical Engineer — vehicle interiors packaging Full-vehicle package bucks · OSCAR H-point & seat-comfort studies · CES 2017 show-car build

Earlier foundation: autonomous airship R&D at IIT Bombay · DOT-PHMSA structural reliability research at Arizona State University · Formula SAE & SAE BAJA.

13+
Years of experience
60%
Supplier cost reductions
40–50%
Component mass reductions
5
Countries in supply chain
50+
Specs owned, one program

Programs, research, education & tools along the way

Pebble Mobility
Arrival
Exponent
Canoo
Faraday Future
Chip Motors
Sensata Technologies
ACG
Maruti Suzuki
DRDO
US Department of Transportation
IIT Bombay — Lighter-Than-Air Systems Laboratory
Arizona State University
Altair Inspire
Sun Devil Motorsports — Formula SAE
Team Manipal Racing — SAE BAJA

Marks reflect employment, program, research, education, and tooling history. All trademarks are the property of their respective owners; no endorsement implied.

How we engage

Built around your program, not our org chart.

Hourly advisory

Architecture reviews, feasibility checks, and manufacturing-method decisions when a program needs senior judgment fast.

Retained scope

Defined workstreams — a seating system, an occupant package, an RFQ round — owned end-to-end with clear deliverables.

Embedded lead

Senior technical lead of record inside your team: CAD execution, studio engineering, prototype builds, supplier coordination.

Credentials

Recognised where seating and interiors people gather.

Speaking & advisory

  • Advisory Board — International OEM Automotive Interiors Circle Association, Hannover
  • Chair & Speaker — Automotive Seating Conference, Munich 2025
  • Speaker & Panelist — Vehicle Interiors Technology Summit, Munich 2026
  • Speaker & Panelist — Automotive Interiors Conference, Bad Nauheim 2025
  • Speaker & Panelist — Automotive Seating Conference, Frankfurt 2024

Publications & education

  • Published — Meeting High-end Sustainability & Circularity Targets in Automotive Seating, 2024
  • Published — Designing a Lightweight Seat for Increased Electrification, 2024
  • MS Mechanical Engineering — Arizona State University
  • MS Project Management — Harrisburg University
  • FAA Part 107 — Licensed Commercial sUAS Pilot

From blank sheet to build.

A full vehicle, a subsystem, a supplier search, a program that needs a steady technical hand, or a line that has to be ready on time — start with a conversation.

sahil@formengg.com  →

or connect on LinkedIn