Interview Questions from TATA Elxsi for Design Engineer | Engineer’s Interview Blueprint

Becoming a Design Engineer at TATA Elxsi is an exciting opportunity, but the interview process requires a strong grasp of both fundamental design principles and industry-specific skills.  

For a Design Engineer, knowledge of materials, manufacturing techniques, CAD software like CATIA, and an understanding of plastic design are essential.  

In this blog, we'll go over some commonly asked questions in TATA Elxsi interviews, offering refined answers that highlight what hiring managers are looking for. 

Interview Questions and Answers 

1. What are plastic joining techniques? 

Plastic joining techniques refer to methods used to combine plastic components securely. Some popular techniques include: 

• Welding (e.g., ultrasonic, laser, and hot plate welding) 
• Adhesive bonding, where specialized adhesives join the plastic parts 
• Snap fits and interlocking joints, which use the material's flexibility to create non-permanent, reusable connections 

2. What is the draft angle for plastics, and why is it important? 

The draft angle in plastic design refers to the slight angle added to the vertical faces of a part to ease its release from a mold during manufacturing. Typically, the draft angle ranges from 1-3 degrees, though it can vary based on the complexity of the mold and the type of plastic. A proper draft angle prevents damage to both the part and the mold, ensuring high-quality production. 

3. What are the surface tools available in CATIA? 

In CATIA, surface tools are used to create and edit complex surfaces in 3D models. Key tools include: 

• Extrude and revolve, which create surfaces from sketches 
• Sweep and loft, which generate surfaces along paths or between sections 
• Join and split, used to combine or separate surfaces 
• Fillet and chamfer, which add curvature or edges to surfaces for smooth transitions 

4. How do you find free edges or gaps in surfaces in CATIA? 

In CATIA, the Boundary command helps identify free edges and gaps in surfaces. This tool highlights edges that aren’t connected to another surface, allowing you to locate and fix gaps that could disrupt a model’s integrity in manufacturing or simulation. 

5. What are some common plastic manufacturing techniques? 

Common plastic manufacturing techniques include: 

• Injection molding, widely used for high-volume production of complex parts 
• Blow molding, suitable for hollow parts like bottles 
• Thermoforming, where plastic sheets are heated and shaped over molds 
• Rotational molding, ideal for larger hollow products with uniform thickness 

6. What are the types of plastics? 

Plastics are generally classified into two main types:

• Thermoplastics, which can be melted and reshaped multiple times (e.g., polyethylene, polypropylene, and PVC) 
• Thermosetting plastics, which, once set, cannot be remelted (e.g., epoxy, phenolic, and melamine) 

7. What are the types of engines? 

Engines are broadly categorized as: 

• Internal combustion engines (ICE), which combust fuel within the engine itself (e.g., gasoline and diesel engines) 
• External combustion engines, where fuel combustion occurs outside the engine, commonly seen in steam engines 

8. How are engines classified? 

Engines are classified by factors such as: 

• Fuel type: Gasoline, diesel, electric, or hybrid 
• Cycle type: Two-stroke or four-stroke cycles 
• Configuration: Inline, V-type, or flat engines 
• Application: Automotive, industrial, or aerospace 

9. What are some methods used in manufacturing processes? 

Manufacturing processes include: 

• Casting, where liquid material is poured into a mold and allowed to solidify 
• Forging, which shapes metal using compressive forces 
• Machining, which involves cutting material to achieve desired shapes 
• 3D printing, or additive manufacturing, where materials are added layer by layer to build the part 

10. Can you describe the different stages of manufacturing? 

The stages of manufacturing typically include: 

• Design and prototyping, where initial ideas are visualized and tested 
• Material selection, to ensure durability, cost-effectiveness, and performance 
• Production planning, where resources and workflows are organized 
• Manufacturing and assembly, the actual building and combining of parts 
• Quality control, ensuring the product meets required standards 
• Finishing and packaging, preparing the product for shipment or sale 

Conclusion 

Interviewing for a Design Engineer position at TATA Elxsi requires not only technical knowledge but also practical understanding of design principles and manufacturing processes.  

With a clear understanding of the questions and concepts covered here, you’ll be well-equipped to present your skills confidently and secure a rewarding career in design engineering. 

Good luck and remember to highlight both your technical expertise and enthusiasm for the field! 

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