5+ years designing, validating and manufacturing high-performance products — drone assembly lines scaling to 500+ units/month, AIS-156-compliant EV battery packs, and HPDC dies that cut component cost by 51%.
End-to-end ownership across the full product development cycle.
Turning ideas into practical designs with advanced CAD modelling — balancing function, manufacturability and cost. e.g. vehicle architecture and 3D packaging layouts with ergonomic studies for an EV two-wheeler.
Building physical prototypes that closely replicate the final product to evaluate design function and manufacturability hands-on — from chassis builds to BLDC smart fans.
FEA simulation plus real-world testing. e.g. RCA on a harness where reverse current during rapid cutoff tripped short-circuit protection — eliminated with a TVS diode at the relays.
Production drawings, supplier development, DFM and ramp planning for 20/100/1,000 units per month — sheet metal, castings, harnesses and full system integration.
Real hardware, shipped and deployed. Each project has a full case study — requirements, key decisions, process and the challenges faced along the way.
Led a 6-engineer team through 6 beta prototypes, an AIS-156 battery pack, 12,000 km durability and ICAT certification submission.
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Low-cost dyno with custom Qt C++ DAQ software — commissioned at Shindengen, Manipal University and RV College.
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Aluminium die-casting die to NADCA guidelines: 51% component cost cut, 500+ rotors cast in production.
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Production tooling for the EV battery cover — core/cavity design with inserts and core pins, machining follow-through and tryout.
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FEA life estimation of frames and propellers; a real modular assembly line, ESD workstations and SKU system for 500+ units/month.
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Complete electro-mechanical build for battery tab welding — enclosure, wiring, custom HMI with programmable sequences.
Read case studyThe Emflux Halcyon BLDC ceiling fan — whose aluminium HPDC rotor die I designed (51% cost cut, 500+ rotors cast) — is on sale on Amazon and Flipkart. Here's what verified buyers say.
Energy-saving BLDC fan with remote, LED light and a 5-year warranty. I designed the high-pressure die-casting die for its aluminium rotor and took the part from prototype to 500+ units in production.
"The fan looks classy and the operation is smooth too. A great value-for-money product!"
"Speed is super even at setting 3, and at full speed it cools my whole room. Very satisfied — anyone buying a BLDC fan, go for this."
"Air flow is awesome — energy efficient and very beautiful. Definitely better than a normal fan."
Smaller design studies and production fixes from across my roles.
Redesigned for lighter weight and less material while eliminating noise and gear interference.
Visualisation and packaging study around the Emflux One electric superbike programme.
A SolidWorks concept for a walking aid for dogs with weak rear legs.
Complete part breakdown of the Halcyon BLDC fan, from cast rotor to canopy.
Tools and methods used on real production programmes.
5+ years across drones, electric vehicles and precision machinery — plus where it started.
M.Tech (Automobile) + B.Tech (Mechanical & Automation)
Dual Degree — Amity University, Noida, 2020 · CGPA 8.2/10
B.Sc Physics (Hons) — Delhi University, 2015
Certified Ansys Professional · Certified Lean Management Professional (British Standards Institute)
Languages: English (fluent), Hindi (native), German (B1)
Competitions, leadership and the motorsport side of engineering.
Open to mechanical design, NPI and product-development roles across drones, EV systems and precision machinery. Have a project, role or question? Send it across.
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