Stefan Kramer (M.Sc. Mechanical Engineering)

Consulting & Independent Engineering Projects (Part-time · Remote)

May 2020 – Present

• Energy System Modeling – Modeled industrial battery energy storage systems (BESS) and microgrid dynamics using MATLAB Simulink and Python.
• Thermal CFD Optimization – Conducted conjugate heat transfer simulations for power inverter enclosures in ANSYS Fluent, enhancing cooling performance by 22%.
• Energy Auditing (DIN EN 16247-1) – Conducted comprehensive industrial energy efficiency audits, identifying over 350 MWh in annual savings.
• CAD Prototyping – Designed custom aluminum structural mounts and waterproof sensor housings in SolidWorks, validated via rapid 3D prototyping.
• Techno-economic Feasibility – Developed automated LCOE (Levelized Cost of Electricity) calculation models for commercial photovoltaic rooftop arrays.
• Standards & Quality – Ensured full compliance with Machinery Directive 2006/42/EC and Low Voltage Directive 2014/35/EU across all prototype iterations.
• Continuous Learning – Deepening expertise in grid integration protocols, hydrogen electrolysis systems, and modular battery cell chemistries.
• Technical Mentoring – Mentored junior design engineers in GD&T tolerance stack-up analysis and finite element meshing best practices.

Senior Systems & Development Engineer · CleanTech Dynamics GmbH (Hybrid Stuttgart)

Apr 2024 – Present

• Battery Storage Architecture – Spearheaded mechanical and thermal packaging of multi-megawatt commercial BESS containers, boosting energy density by 18%.
• CAD Enclosure Design – Modeled complete structural frames, HVAC ducting, and liquid cooling distribution blocks in Siemens NX, cutting assembly time by 25%.
• FEM Structural Verification – Executed static, modal, and fatigue simulations in ANSYS Mechanical to ensure seismic resistance and transport load compliance.
• Design for Manufacturing (DFM) – Optimized sheet metal stamped components and extruded aluminum profiles, reducing unit fabrication costs by 12%.
• Test Bench Validation – Established comprehensive test bench procedures and sensor instrumentation (PT100, strain gauges, flow meters) for thermal runaway containment.
• CE Certification & Compliance – Led risk assessment workshops (FMEA) and authored technical dossiers for CE conformity under the Machinery Directive 2006/42/EC.
• Supplier Quality Management – Conducted technical audits and PPAP sampling approvals for structural steel and cooling system suppliers.
• Stage-Gate Product Delivery – Steered cross-functional milestones between electrical engineering, automation, and procurement on schedule.

Mechanical Development Engineer – SüdTech Engineering AG (Stuttgart)

Jul 2021 – Mar 2024

• Thermal & Fluid Simulation – Developed 3D steady-state and transient CFD models for commercial heat pump evaporators and refrigerant loops in ANSYS Fluent.
• CAD Component Development – Designed high-precision die-cast aluminum pump volutes and polymer impeller housings in SolidWorks with strict GD&T.
• Prototype Commissioning – Built physical prototype rigs, calibrated high-accuracy Coriolis flowmeters, and correlated experimental pressure drop curves with CFD data.
• Tolerance Stack-up & FMEA – Led tolerance calculations (worst-case and statistical RSS) and design FMEAs to prevent sealing failures under extreme thermal cycling.
• Interdisciplinary Collaboration – Partnered with controls software engineers to define sensor placement and actuator response curves.
• Energy Efficiency Optimization – Enhanced heat transfer coefficient by 16%, securing top-tier ErP energy efficiency classification.
• Engineering Documentation – Authored manufacturing drawings, assembly instructions, and bill of materials (BOM) within Siemens Teamcenter PDM.
• Engineering Internship (Apr '20 – Sep '20) – Performed mechanical stress testing, hydraulic pressure endurance runs, and metallographic material evaluations.

Specialization in Energy Technology, Computational Fluid Dynamics (CFD), Structural Mechanics (FEM), and Renewable Energy Systems.

Core foundations in Technical Mechanics, Thermodynamics, Materials Science, Machine Elements, and CAD Design.

Academic Achievements

• Master Thesis Award – Recognized for innovative thermal packaging of high-density lithium-ion battery modules
• Advanced research projects in convective heat transfer and turbomachinery fluid modeling