ATD Engineer - Design & Testing

• Apr 2023 - Present

Motorcycle Designer

• Mar 2022 - Mar 2023

Responsible for surface modelling & frame design with the ability to implement base dynamic vehicle geometry which will driving both the FEA & Design Change for the motorcycle. Good ability to understand & undertake hand calculations for ladder weight, Trial impacts with fork offset & wheelbase, manual chassis load analysis and material impact analysis. Highly skilled in taking the project from scratch concept design to final production stage with the proven experience working in concept, final surface modelling, prototyping, additive manufacturing for prototype & final production, mould tool design, helping the manufacturing team in build manual, and helping the R&D to improve & solve the problems in existing & future concept models. Proven track record in Design Improvements for the manufacturing & assembly efficiency on the existing motorcycle models which helped the manufacturing team to recover 47% in manufacturing cost. GD&T implementation with regular drawing checks and approvals has comparatively improved the quality of the machined components & assembly procedure. Highly capable of creating technical reports & design presentations for high level management, marketing team, customers and suppliers. Show less

Mechanical Design Engineer

• Oct 2021 - Feb 2022

Responsible for THOR 50M, THOR 5F, WorldSID-5, & Q-Series in surface design, mould tool design, design optimisation, drawing optimisation and helped the team in project management with ability to deliver the high precision project on time and with in budget. GD&T implementation for the mould tool high precision machining had brought down the part failure in the R&D stage down to 30%. Also helped the manufacturing team for the draft angle decisions and material temperature decisions for the mould release. Highly skilled in surface repair and part optimisations for the NHTSA extracted parts and also helped the team in creating a efficient top level design assembly which helped the NPI team & Manufacturing team in the production stage. Show less

Mechanical Design Engineer

• Oct 2020 - Oct 2021

Responsible for complete exterior & driver cockpit surface modelling and Fibreglass mould tool design with the ability to take the project from concept design to final manufacturing & assembly stage. Efficient in implementing different manufacturing methods including factory layout for the efficient manufacturing and assembly, time analysis & improvements for each section of the process, and also implemented H&S for every process & section for the factory. Proven track record in implementing additive manufacturing which eventually replaced injection moulding process and recovered almost 65% in the product manufacturing, also implemented bespoke 3D printed new products as accessories for new & existing customers. Implemented a new CAD file management system for the design productivity which increased the productivity by 30%, also implemented works order for bespoke and standard assembly procedures which increased the productivity by 23%. Show less

Mechanical Design & Development Engineer

• Feb 2020 - Oct 2020

Responsible for tooling design for automotive hybrid motor, buss pass sleeve design, motor non drive end panel design, and additive manufacturing for prototyping. Highly skilled in implementing GD&T, surfacing modelling, efficient assembly model, stacking & concentric tolerance calculation, high precision manufacturing drawings, FEA, CFD analysis, SOP and works order creation. Collaborated with the manufacture team in implementing NPI, NPD, SPC, Process Mapping, Product routing and continues improvements. Worked in collaboration with customers like Haas F1 for bespoke motor manufacturing for their 2021 F1 car model with the specification of critical temperature management. Show less

Formula Student Chassis Design Engineer

• Sep 2018 - Jan 2020

Responsible for 2019, 2020 formula student electric vehicle monocoque chassis design & optimisations with the ability to carry out FE analysis for Torsional Stiffness with stable load and real track data. Also helped the aerodynamic team in the surface design of the front wing and rear wing, Highly skilled in validating the design, FEA and CFD analysis agains the real life result data using different testing method including real time wind tunnel and torsional test bed. Proven ability in carbon fibre layer optimisation with the extracted data from FEA and real time torsional analysis. Implementing the standard industrial design & manufacturing process like GD&T, Efficient Assembly, Design Check, Design Approvals, Works orders, organised FEA & CFD data had helped us to secure the 1st place in Design & Optimisation for Formula student UK 2019, Also won the overall championship that year. Show less

Design and Manufacturing Intern

• Apr 2019 - Sep 2019

Responsible for surface design for the new model lawn movers, mechanical part design, factory layout for the manufacturing & assembly efficiency, vacuum form mould tool design and injection mould tool design. Highly skilled in sheet metal chassis design for the new model, DFMEA, Works order implementation for manufacturing improvements, product prototyping using additive manufacturing methods. Proven track record in time analysis and improvements for the assembly line improvements which had increased the production of the lawn mover on the existing assembly line from 10 per day to 13 per day. Collaborated with different parts of this business to create a efficient factory layout and also implemented and new assembly line for the new model assembly with efficiency of assembling 13 lawn movers per days. Show less

Mechanical Design Engineer

• Aug 2017 - Aug 2018

Responsible for magnetic component design, water jacket design for the motors, ignition coil component design, CFD analysis for the motor coolant jackets, project management, budget management for the bespoke projects. Skilled in implementing GD&T and BS 8888 to both design and drawing for the precision manufacturing to the customers like Greves, MMG India Ltd and Hyundai Motors India Ltd. Collaborated with design and manufacturing in product routing, process development & improvement, SOP, process mapping, /new product development and NPI. Implemented a efficient manual part numbering system & product routing system which has increased the productivity by 20% on both design and manufacturing. Show less

Design and Manufacturing Intern

• Feb 2017 - Apr 2017

Design and Core Analysis of Part Stock Optimisation and Improvement • Project was mainly based on the strategic service management of the company; the parts were analysed from scratch to finish, Engineering drawings were analysed and cross verified with selected number of products. • As per the data obtained part stock have been optimised and improved. • This project has recovered 5% of the company’s total loss. Elimination of Process Rejection of Gear Cone Height Undersize and Oversize • Project focused on the cone height issue which was raised in 2017 which has eventually had a gear failure on Hyundai i20 2017 model after 150,000 miles. • Part drawings are verified against floor operations. • Gear measurements are done on the floor before and after heat treatment. • The problems faced are resolved with the implement of new solutions. Show less