Mallikarjun Sabarad
Singapore
Summary
Engineering professional prepared for high-impact roles with extensive experience in leading cross-functional teams and managing large-scale projects. Known for strong focus on collaboration and achieving results, adapting seamlessly to changing project needs. Possesses technical acumen and strategic planning skills that drive engineering excellence and innovation.
Overview
25
25
years of professional experience
Work History
Principal Engineer
Dyson Singapore
04.2024 - Current
- Spearheaded NPI/NPD initiatives for Hair Care and Floor Care Vacuum Cleaner categories, driving product maturity from concept to mass production
- Served as Tooling Program Lead for Dyson’s flagship products including Digital Motor, Supersonic Hair Dryer, Airwrap Hair Curler, Dyson Zone and OnTrak Headsets, and Environmental Care platforms
- Directed tooling validation and process development for high-precision plastic and hybrid components, ensuring manufacturability and design integrity
- Applied scientific injection moulding techniques to optimize process parameters, reduce cycle times, and enhance product quality
- Collaborated extensively with global RDD teams to align design intent with manufacturing capabilities and tooling feasibility
- Oversaw large-scale contract manufacturing operations, ensuring supplier readiness, tooling scalability, and production ramp-up
- Managed annual CAPEX of approximately $200 million for tooling development and manufacturing engineering across global programs
- Championed sustainable tooling strategies, including post-consumer resin integration and advanced moulding technologies
- Supported development of lens moulding and FIM components for premium aesthetic and functional finishes
- Associate Principal Engineer (May 2021 – Apr 2024)
Program Manager
Univac Precision Engineering
01.2009 - 05.2021
- Directed NPI/NPD programs for Class III medical devices including vessel sealing tools, eye care consumables, and DNA sequencing platforms
- Delivered turnkey solutions from DFM to industrialization, including tooling development, FAT, DOE, PFMEA, IOPQ, and PPAP
- Managed contract manufacturing partnerships across Asia, ensuring quality, cost, and delivery targets were met
- Utilized transfer moulding and scientific injection moulding to develop complex hybrid assemblies with regulatory compliance
- Collaborated with RDD and operations teams to streamline product launches and scale production
- Senior Design Engineer (Sep 2005 – Jul 2009)
Design Engineer
VS Industry BHD
05.2003 - 08.2005
- Designed tooling and product solutions for consumer electronics and packaging applications
- Supported NPD activities through prototyping, testing, and engineering documentation
- Worked with diverse materials including rubbers, metals, and engineered plastics
Design Engineer
Varroc Engineering & GIC Pvt Ltd
09.2000 - 04.2003
- Developed and qualified molds for automotive and consumer components
- Participated in early-stage product development and tooling feasibility assessments
- Supported die casting and metal injection moulding projects for high-strength applications
Education
Bachelor of Engineering - Mechanical
University of South Australia
Diploma - Tool and Die Making
NTTF
Skills
- End-to-End NPI/NPD Execution for Medical Devices, Life Sciences, Consumer Electronics, Hair & Floor Care Products
- Tooling Design & Development Scientific Injection Moulding Transfer Moulding
- DFM/DFMEA Lean Manufacturing Six Sigma ISO 9001 & ISO 13485 Compliance
- Large-Scale Contract Manufacturing Management Operations Management Supplier Development
- Cross-Functional Collaboration with RDD Teams for Product Innovation
- CAPEX Management (~$200M Annual Spend) Cost Estimation Project Budgeting
- CAD Expertise: AutoCAD, Unigraphics, Solid Edge
- Materials & Processes: Commodity Plastics, Engineering Plastics, Metals, Rubbers, Die Casting, Metal Injection Moulding, Film Insertion Moulding, Lens Moulding
Career Highlights
- Over 25 years of experience in precision plastics, tooling, and manufacturing across medical, life sciences, and FMCG sectors
- Category tooling lead for Hair Care and Wearables at Dyson
- Tooling Program Lead for Dyson’s Digital Motor, Supersonic Hair Dryer, Airwrap Hair Curler, Dyson Zone and OnTrak Headsets, and Environmental Care product lines
- Program lead for Class III medical device tooling (Pacemaker Headers) and insulin patch delivery systems
- Design lead for innovative 96 & 384 Well Drop Array products
- Delivered NPI/NPD for metal-plastic hybrid assemblies using ultrasonic welding, adhesive bonding, transfer moulding, and lens moulding
- Applied scientific injection moulding principles to enhance process control and product reliability
- Extensive experience managing large-scale contract manufacturing and operations across Asia
- Proven track record of successful collaboration with RDD teams to deliver manufacturable, high-performance products
- Directed CAPEX investments exceeding $200 million annually, optimizing tooling infrastructure and manufacturing engineering capabilities
Timeline
Principal Engineer
Dyson Singapore
04.2024 - Current
Program Manager
Univac Precision Engineering
01.2009 - 05.2021
Design Engineer
VS Industry BHD
05.2003 - 08.2005
Design Engineer
Varroc Engineering & GIC Pvt Ltd
09.2000 - 04.2003
Diploma - Tool and Die Making
NTTF
Bachelor of Engineering - Mechanical
University of South Australia
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