Mechanical Design Engineer · Drones · EV Systems · Precision Mechanisms

I take electro-mechanical products from concept to production.

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%.

🇦🇺 Relocating to Australia · Mechanical Engineer (ANZSCO 233512) · Core Skills Occupation List
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Finished electric two-wheeler — production prototype
5+
Years Experience
51%
Component Cost Cut (HPDC)
500+
Units/Month Line Designed
6
EV Prototypes Built
How I Work

From Concept to Production

End-to-end ownership across the full product development cycle.

01

Concept Generation

Transforming 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.

02

Prototype

Building physical prototypes that closely replicate the final product to evaluate design function and manufacturability hands-on — from chassis builds to BLDC smart fans.

03

Testing & Validation

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.

04

Manufacturing

Production drawings, supplier development, DFM and ramp planning for 20/100/1,000 units per month — sheet metal, castings, harnesses and full system integration.

Portfolio

Featured Projects

Real hardware, shipped and deployed. Each project has a full case study — requirements, key decisions, process and the challenges faced along the way.

Six electric two-wheelers ready for certification
Apeiron Mobility · Vehicle Programme

Electric Two-Wheeler — Concept to Certification

Led a 6-engineer team through 6 beta prototypes, an AIS-156 battery pack, 12,000 km durability and ICAT certification submission.

Read case study
Inertial dynamometer with motorcycle
Emflux Motors · Test Systems

Inertial Dynamometer

Low-cost dyno with custom Qt C++ DAQ software — commissioned at Shindengen, Manipal University and RV College.

Read case study
HPDC die open showing core and cavity
Emflux Motors · Tooling & Casting

HPDC Die — BLDC Fan Rotor

Aluminium die-casting die to NADCA guidelines: 51% component cost cut, 500+ rotors cast in production.

Read case study
Battery cover die lifted with crane straps
Apeiron Mobility · Tooling

Battery Pack Cover Die

Production tooling for the EV battery cover — core/cavity design with inserts and core pins, machining follow-through and tryout.

Read case study
Drone isometric render
Skylark Drones · NPI & Analysis

Drone Frame & Assembly Line

FEA life estimation of propellers and frames; modular assembly line designed for 500+ units/month.

Read case study
Automatic spot welder render
Emflux Motors · Industrial Automation

Spotmeister — Automatic Spot Welder

Complete electro-mechanical build for battery tab welding — enclosure, wiring, custom HMI with programmable sequences.

Read case study
Capabilities

Skill Sheet

Tools and methods used on real production programmes.

CAD & Design

SolidWorksPTC CreoFusion 360InventorOnshapeGD&T (ASME Y14.5)Tolerance Stack-upSheet MetalSurfacingWeldments

Analysis & Simulation

Ansys StructuralAnsys FluentNastran FEAModal AnalysisFatigue / Life EstimationThermal Analysis

Manufacturing & NPI

DFM / DFMAHPDC & Injection MouldingAssembly Line DesignBOM / PDMSupplier DevelopmentLean (Certified)Milling & LatheMIG Welding3D Printing (FDM/SLA)

Electrical & Harness

AutoCAD ElectricalInventor HarnessWireVizNailboard DrawingsAIS-156 ComplianceCrimping & Soldering

Software & Controls

Qt C++Python GTK3LinuxCNC HMIRaspberry PiESP32 / MSP430Google Scripts

Visualisation

KeyShotBlenderAdobe InDesignPhotoshopTechnical Documentation
Career

Experience & Education

5+ years across drones, electric vehicles and precision machinery.

APR 2025 – PRESENT

Mechanical Solution Engineer

Skylark Drones — Bengaluru, India
  • Modular drone assembly line targeting 500+ units/month — takt time, scalability and cost optimised
  • FEA life estimation of propellers; static/modal/fatigue analysis of frames
  • Shenzhen supplier scouting; NPI transfer to EMS partners for SMT and box-build
DEC 2022 – APR 2025

Program Head — Mechanical Systems

Apeiron Mobility — Bengaluru, India
  • Led 6-engineer team; 6 beta EV prototypes built, 2 submitted for ICAT certification
  • 3.2 kWh AIS-156-compliant swappable battery pack; 12,000 km durability programme
  • Production BOMs and drawings for 20/100/1,000 units-per-month ramp
DEC 2020 – DEC 2022

Mechanical Design Engineer / Solutions Expert

Emflux Motors — Bengaluru, India
  • Aluminium HPDC die to NADCA guidelines — component cost cut 51%
  • BLDC smart ceiling fan from prototype to certified production
  • E-rickshaw gearbox redesign; sheet-metal enclosures and heatsinks with thermal analysis; mentored 3 engineers

Education

M.Tech (Automobile) + B.Tech (Mechanical & Automation)
Dual Degree — Amity University, Noida, 2020 · CGPA 8.2/10

B.Sc Physics (Hons) — Delhi University, 2015

Achievements & Certifications

Certified Ansys Professional · Certified Lean Management Professional

Vice-Captain & Chief Design Engineer, Amity BAJA Racing (SAE) 2018–19 · First place, ASME-chapter CAD competition · Published research on metal-matrix nanocomposites

Let's build something that ships.

Relocating to Australia — Mechanical Engineer (ANZSCO 233512) on the Core Skills Occupation List, Engineers Australia assessment in progress. Open to employer-sponsored (482) and PR-pathway roles.

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