Sumit Sharma

Technical Specialist||Passive Safety||McLaren||Ex-Volvo||Ex-Mercedes

London Area, United Kingdom

About

I’m a dedicated automotive safety engineer with a passion for leveraging cutting-edge technology to protect lives. With global experience at McLaren, Mercedes-Benz, and Volvo, I specialize in Computer-Aided Engineering (CAE), passive safety systems, and biomechanics, shaping the future of passive safety for some of the world’s most iconic vehicles. As a Technical Specialist for Passive Safety and Biomechanics at McLaren, I lead the safety DNA of next-generation supercars. My work focuses on advanced crashworthiness analysis, occupant & interior exterior safety assessments, testing protocols, and homologation strategies to ensure safety compliance and performance. Previously, I engineered side-impact safety systems for Mercedes-Benz’s flagship models (S-Class, E-Class, C-Class, B-Class) and drove innovations in pedestrian protection and frontal collision safety at Volvo. At SAFER, I conducted crash test film analysis to uncover critical biomechanical insights, enhancing occupant protection. My expertise spans the entire safety development lifecycle—from digital CAE simulations and crash test predictions to validation testing, data analysis, and homologation—delivering solutions. Core Strengths: ✔ Crashworthiness & Occupant Safety ✔ Restraint Systems & Biomechanics ✔ Pedestrian Protection ✔ CAE Simulation & Crash Testing ✔ Validation Testing & Homologation ✔ Data Analysis & Correlation

Experience

  • McLaren Automotive Ltd (Full-time · 6 yrs 11 mos)
    • Technical Specialist- CAE Passive Safety
      Sep 2024 - Present · 1 yr 11 mos

    • Senior Passive Safety & Biomechanics CAE Engineer
      Sep 2019 - Aug 2024 · 5 yrs

      CAE Passive safety (major) and crashworthiness (minor) evaluation of McLaren cars for Front, Side-impact and restraint & component analysis. • Responsible for the planning and execution of passive safety development programs to support engineering sign off and homologation of future McLaren vehicles for global markets. • Ownership of digital CAE development for passive safety. • Development of unprecedented concepts pertaining to occupant safety and product development of Mclaren supercars with design engineers, interior engineers and attribute leaders. • Showcase the feasibility, contribution in product development and implementation in the vehicle. • Subsystem, component-level analysis to enhance functionality and performance further. • Addressing the possible challenges before testing, Providing frugal countermeasures, Analysis of test results, correlation and making sure a pass for a legal requirement. • Exposure of composite parts, Layup defination and Analysis, manufacturing challenges.

  • VESC CAE Engineer at Volvo Car Sverige
    Jan 2018 - Jul 2019 · 1 yr 7 mos

    Development and Evaluation of a Submarining Criterion At Volvo Cars, I contributed to advancing occupant safety by developing and validating robust criteria to predict and reduce the risk of submarining during vehicle crashes. • Developed prediction criteria for three key human surrogates: HIII 5th Female, THOR 50th Male (Test Device for Human Occupant Restraint), and THUMS 50th Male (Total Human Model for Safety). • Created probabilistic functions to quantify submarining risk, enabling a more data-driven understanding of safety outcomes. • Verified the accuracy and predictive value of candidate criteria against physical crash test results, ensuring strong correlation between virtual and real-world performance. • Applied the criteria to evaluate how changes in restraint system geometry influence submarining risk and provided recommendations for design improvements, directly supporting safer restraint system development.

  • CAE-Analyst at Mercedes-Benz Research and Development India
    Jul 2014 - Jun 2017 · 3 yrs

    My primary responsibility at MBRDI was to evaluate Mercedes-Benz cars for the different regulations, load-cases and company standards(e.g. FMVSS214, USNCAP, China-NCAP and IIHS etc), and to give countermeasures in order to achieve the goal of 5-star safety ratings. I was among the one of the 3 simulations experts on rear occupant side impact safety during my tenure across Daimler for MB cars. Some of the major responsibilities are mentioned below: • Robustness analysis to make sure design solution performed well in all possible scenarios and didn’t hamper the functionality of other domains. • Contributed to design guidelines of interiors modules such as (door-trims, window-bag, side-airbag, seats) and hence directly contributed to product development of aforementioned modules. • In addition to core responsibility, worked on integrity and performance check of subsystem modules (such as side airbags, seating systems, door-trims) and coordination with suppliers to develop a subsystem. Additionally, I got a practical understanding of injury-biomechanics, human anatomy and dummy technology along-with comprehensively setting up the load-cases and exposure of HBM (Human Body Model) on challenges in simulations. Having worked in cross-functional teams (front crash, child safety, Out of position, interiors etc.) significantly enhanced my understanding of the field of passenger safety, as it made me aware of the various facets and correlations of the simulations and tests. It also introduced me to the limits and trends prevalent in the passenger safety domain.