Mechanical Design Engineer

Special Purpose Machine Design

Special Purpose Machines (SPM) are those machine which are not available Off the Shelf. Automation and technological advancements have drastically changed the FMCG, Automobile, Aerospace & Pharma manufacturing industries. One such area is Special Purpose Machine (SPM) design.

As SPM is not created on standard manufacturing machine, customized design is crucial to ensure various parameters such as product performance, production output rate and safety, specific to each organization goals. The Special Purpose Machines are Generally Product Specific & they are required to be Designed & Developed for each Specific Requirement.

I helped many companies develop technologically advanced machines that met their specific needs and helped with the design of the specialized machines. No matter how small or big your design requirements are, I’m equipped to cater to it from the initial concept to complete design along with end-to-end design & manufacturing support.

You have lot of ideas but struggling to give it a shape, size, materials, arrangements of various electromechanical components to build a full functional engineering machine/product for different applications, you are at the right place and that’s exactly what I do. Below is the list of what I will be able to help you with

• New Concept Design (Sketch & 3D).
• Adoptive design to existing design/machine.
• Developments/Improvements to existing design.
• Detailed Design with Manufacturing & Assembly Drawings.
• Manufacturing Support.
• Assembly & Validation of design.

Product Design

Product designers help make products which aren’t just easy and delightful (or at least satisfying) to use, but also fine-tuned to do consistently well in the marketplace. They help define product goals, create product roadmaps and, ideally, help brands release successful products.

Designing a new product goes through an analytical process and relies on a problem-solving approach to improve the quality of life of the end user and his or her interaction with the environment. It is about problem-solving, about visualizing the needs of the user and bringing a solution.

The design process is divided into many different phases, which include various form of sketching and prototyping. However, sometimes the idea starts from a problem people may experience, and designing a solution to solve it.

Do you have an idea & make it in to a product to market? Having trouble with your existing product & want to solve? Or any other support you need on your product development and you looking for someone to help you with, below are the areas I will be able to help you with,

• Industrial Design (Parametric & Non-Parametric).
• New concept design from scratch (sketch & 3D).
• Design Optimization of existing product.
• Detailed Parametric Design.
• Design for 3D printing.
• Manufacturing drawings for Prototype.
• Manufacturing Drawings for Production.
• Prototype manufacturing.
• Support for Design Verification, Validation & testing.

Industrial Automation Design

       Maintaining strict quality control and keeping production running at maximum efficiency has become too complex for people to manage directly. Modern high-speed manufacturing requires extensive networks of instrumentation, controls, and automation systems throughout production, storage, and shipping operations. Today’s highly increasing competitiveness over the industry demands high quality and most consistent products with a competitive price. To address this challenge number of industries considering various new product designs and integrated manufacturing techniques in parallel with the use of automated devices.

       Automation of factory or manufacturing or process plant improves production rate through a better control of production. It helps to produce mass production by drastically reducing assembly time per product with a greater production quality. Integration of various processes in industry with automated machineries, minimizes cycle times and effort and hence the need of human labour gets reduced.

       From robotic handling systems to vision quality inspection systems, fully & semi automated packaging, pick & Place robots, and automated storage and retrieval systems, I have helped clients implement cutting-edge technology to meet their production, quality, and efficiency goals.

I can help you automate/semi-automate any of your production lines with supports below,

• Field study to understand existing process(Manual or semi Automated).
• Understanding the problems in existing process.
• Optimize & arrive at effective process to solve the problem.
• Concept proposal in 3D design.
• Manufacturing drawings.
• Manufacturing Support.
• Design validation after manufacturing if required.

Jigs & Fixtures Design

The successful running of any mass production depends upon the interchangeability to facilitate easy assembly and reduction of unit cost. Mass production methods demand a fast and easy method of positioning work for accurate operations on it. Jigs and fixtures are specially designed so that large numbers of components can be machined or assembled identically, and to ensure interchangeability of components.

More and more jigs & fixtures are employed in electronics manufacturing for assembly, dis assembly, calibration & various electrical testing of components to make defect free products to market to have edge in the market and to suit the raising demand of the market.

From screw fixing, leak testing, pressing jigs, calibration fixtures to inspection gauges & fixtures, I have helped clients in developing large numbers of fixtures which helped clients to improve their productivity by reducing human errors and achieving great consistency in quality.

I can help you automate/semi-automate any of your production lines with supports below,

• Jigs/ Fixtures for machining process.
• Jigs/ Fixtures for assembly of plastic/metal components.
• Jigs for various testing of plastic/electrical/metal components.
• Fixtures for inspection purposes.
• Gauges for Dimensions Inspection.
• Welding Fixtures.
• Assembly Fixtures.
• Manual/Automatic Pressing Jigs.

Component Design

Most products are made up of one or more components. Each component will need to be manufactured and the process used will depend on the components' application and specification. Choosing the optimal material and manufacturing process combination for a given engineering component application is mostly non-trivial and involves considerable design expertise and experience. This choice is not made in isolation of a lot of other conflicting design issues, technical and non-technical, as well as the need to satisfy interface requirements with adjoining components.

I can work with assemblies of various complexity ranging from a couple of parts to several thousand. I can design your complete product, addressing each component individually and ensuring that all components fit and function together.

I have vast experience of designing components for the most common low to high volume manufacturing processes including

• Plastic moldings.
• Metal castings.
• Extrusions.
• Sheetmetal fabrications.
• Welding fabrications.
• Machined components.

I understand the limitations of each process but also work alongside suppliers to push process boundaries to produce innovative solutions. I have close links with suppliers and toolmakers specializing in a range of production processes.

I have spent a great deal of time with various factories working through assembly flow lines to ensure products are assembled correctly and efficiently.

I can help you automate/semi-automate any of your production lines with supports below,

• Understand individual component design requirement.
• Analyse various feasible method of manufacturing with pros & cons.
• Design of component for suitable manufacturing method.
• Design for prototype development.
• Improving design based on prototype observations.
• Finalize the component design for production.

Reverse Engineering

Reverse engineering, sometimes called back engineering, is a process in which software, machines, aircraft, architectural structures and other products are deconstructed to extract design information from them. Often, reverse engineering involves deconstructing individual components of larger products. The reverse engineering process enables you to determine how a part was designed so that you can recreate it.

In some cases, the only way to obtain the design of an original product is through reverse engineering. With some older products that have not been manufactured for 20 years or more, the original 2D drawings are no longer available. Often, there will be no way to contact the original manufacturer, as the company may no longer be in business. In a highly competitive global market, manufacturers constantly strive to shorten lead-times to bring a new product to market. With reverse engineering, a 3D model can be quickly captured in digital form and remodelled if necessary or exported for a variety of manufacturing methods.

CAD is used to create two- or three-dimensional (2D or 3D) graphical representations of physical objects. In product and industrial design, CAD is used mainly for the creation of detailed 3D solid or surface models, or 2D vector-based drawings of physical components. Reverse engineering requires a series of steps to gather precise information on a product’s dimensions. Once collected, you can store the data in digital archives. Often, engineers will enhance the design with new developments and innovations. Sometimes, it is possible to replicate the original model exactly and I have been able to help in below areas,

• Access the physical component (Part/assembly) (Plastic/Metal).
• Identify the system’s components and their interrelationships in case of assembly.
• Create representations of the system in another form or a higher level of abstraction.
• Hand/CMM measurements of components depending upon the complexity & accuracy expected.
• Recreate the design in 3D CAD.
• Replicate same design/improving as per requirement.
• Producing detail drawings along with material for building the design.
• Reverse Engineering of non-parametric model to parametric model in CAD.

Enclosure Design

While the power of a hardware product comes from its internal components, a product is typically recognized by its enclosure, the outer shell that encloses electronic products, making them appealing and user-friendly. Most electronic products, appliances or machines have some sort of a housing or enclosure that protects and holds all the internal components together.

In today’s competitive market, for a product to be successful, it is important to have a custom designed, sleek and user-friendly product enclosure that also does the job of enticing and delighting the consumer. The technology inside your product may be the most advanced, but if it fails to visually entice the buyers, you may be hindering the chances of your success.

I design custom product enclosures that are aesthetically pleasing while being reliable and easy to manufacture. We work on a variety of products like consumer electronics, machine enclosures, instruments, handheld products, wearables, IOT and more.

I have hands on experience on developing Plastic enclosure, Handheld enclosure, Aluminium enclosure, Diecast aluminium box, Stainless steel box, IP67 waterproof enclosure, Junction box, 19"rack mount enclosure, PCB enclosures for electronics devices, Variety of enclosures as handheld enclosures, wall mount enclosures or desktop enclosures, ergonomically sized for handheld use and Dustproof plastic enclosures in IP67, IP65, and IP54 protection standards. I can help you with,

• Understanding Product requirements.
• Arriving at overall dimension by building a shell consists of all internal components.
• Conceptualize Industrial Design.
• Choosing materials, finishes, colours etc.
• Considering mounting options.
• Considering standard certifications requirement if any.
• Engineering detail design.
• Prototyping.

FEA Solutions

Finite element analysis (FEA) is the process of simulating the behavior of a part or assembly under given conditions so that it can be assessed using the finite element method (FEM). FEA is used by engineers to help simulate physical phenomena and thereby reduce the need for physical prototypes, while allowing for the optimization of components as part of the design process of a project. FEA enables you to predict potential design issues and therefore minimize risk to your product, profits, and your business.

FEA uses mathematical models to understand and quantify the effects of real-world conditions on a part or assembly. These simulations, which are conducted via specialized software, allow engineers to locate potential problems in a design, including areas of tension and weak spots. FEA can be used to optimize the performance of a new product, verify an existing product, or modify a product for a new condition.

FEA can also be used to:

• check your design is on track during the design process
• check calculations, when hand calculations are too difficult.
• optimize stress, mass, heat, etc. to get the best results before the manufacturing stage of the project.
• understand structural behavior and therefore remove uncertainty in the design phase.

By integrating virtual testing early in product development, users can develop more accurate and reliable product designs while reducing the need for costly prototyping.

Types of FEA simulations that I can help you with,

• Linear Static & Dynamic Stress Analysis.
• Non-Linear Analysis.
• Fatigue Analysis.
• Welding structure simulation & optimization.
• Frequency Buckling or Collapse Simulation Analysis.
• Vibration analysis.
• Drop test & Impact.
• Thermal Stress & Heat Transfer Analysis.
• Motion Analysis.
• Mechanism Simulation.
• Design Optimization.
• Plastic & Rubber Part Analysis.
• Structural Optimization.

Geometric Dimensioning and Tolerancing (GD&T)

Geometric Dimensioning and Tolerancing (GD&T) is a design approach and manufacturing mechanism that helps engineers and designers communicate how to bring a part design to life. When documented correctly using GD&T, it is possible to build a part that exactly matches its on-paper plans.

GD&T uses a symbolic language to indicate how significantly part features can deviate from the geometries listed in the design model. This language contains all relevant details involved in fabrication, including dimensions, tolerances, definitions, rules, and symbols that communicate a component’s functional requirements. These all currently follow ASME Y14.5M-2009 (previously ASME Y14.5M-1994).

While many applications benefit from GD&T, there are certain situations in which the process provides fundamental assistance, including scenarios in which critical or interchangeable parts fit into a larger assembly, tolerance analysis needs simplification, thus it becomes clear to have an in-depth hands-on exposure to when, where and how to use GD&T.

My Training Courses:

• Basic level with industry examples.
• Intermediate level with industry examples.

My Training Courses:

• Component/Assembly level with industry examples through “Worst Case Analysis”.
• Component/Assembly level with industry examples through “Worst Case Analysis”.

Design for 3D Printing

Additive manufacturing, aka 3D printing, is the process of producing 3-dimensional objects from a computer file, where the part is built by adding material layer-by-layer. Today, more companies in a variety of industries are embracing the 3D printing process as it presents many significant advantages over the more traditional manufacturing methods of subtractive manufacturing and injection molding.

One of the biggest advantages of 3D printing technology is Rapid Prototyping. Rapid prototyping is the ability to design, manufacture, and test a customized part in as little time as possible. With 3D printing techniques, a business can design a part, manufacture it in-house on a professional 3D printer, and test it, all within a few days (and sometimes even less). For small production runs and applications, 3D printing is the most cost-effective manufacturing process.

Different 3D printing processes have different capabilities and different design restrictions like choosing correct wall thickness, overhangs, deciding on round corners to avoid warping etc. Each vary in the way they form plastic and metal parts and can differ in material selection, surface finish, durability, and manufacturing speed and cost. So, it is important for designers to have thorough knowledge on each of the process in order to design products for specific method of 3D printing technology.

I have a great understanding on both Polymer 3D Printing Processes (SLA, SLS, PolyJet, DLP, MJF, FDM) & Metal 3D Printing Processes (DMLS & EBM) and I have been helping companies on design and 3D printing activities such as below,

• Design of component for suitable 3D printing technology (Polymer or Plastic).
• Review of new/existing design for 3D printing.
• Converting designs from conventional design to design for 3D printing and vice a versa.
• Design evaluation for different methods of 3D printing process.
• 3D printing manufacturing support for prototype/regular production.

Trainings I Provide

Learning, as they say, is a never-ending process and is very crucial for people to keep growing. And when you are an employee, learning becomes your force to move ahead. Learning has been a concept that has evolved with time, which does not end with a degree or after you settle down with a good job. It is a lifelong process. You always find something new to learn every day.

And somehow, between all the chaotic developments, we have adopted different ways and means to learn new things. To keep up with the advancements of today's world, you need to keep yourself updated with new skills and knowledge. According to a survey, 54% of employees have said that it is essential for them to get training and develop new skills throughout their work-life to keep up with the changes in the workplace. With today’s rapidly changing pace of the occupation market, employees need to stay informed concerning new technology and knowledge. It is heartening to note that many organization value industrial training as an approach to prepare future employees and consider offering such training programs as their corporate social responsibility.

Continuous learning is most effective when the individual has a desire to learn and grow regardless of their present knowledge & current position in their career. This is especially useful for constantly changing industries, which require professionals to stay constantly updated with industry trends and learn modern skills.

Knowledge is now at everyone’s fingertips. Those not making use of this opportunity will remain where they are – their capabilities diminishing in importance. Always have a curious mind. Explore different topics and don’t be afraid to ask for clarity. Be inquisitive, and if your intent is sincere, there will be people who will help and support you in your journey.  

An engineer who gets the industry-oriented training will be able to hone skills and gain knowledge in his or her technology field. My trainings will help you boost your confidence and enhance your capabilities. Below are the list of trainings that I provide for individuals and companies. So, what are you waiting for?

• Solidworks CAD alone or with technical domain like Sheetmetal, Jigs & Fixture Design, Product Design, Casting Design, Weldment Structure Design.
• Autodesk Inventor CAD alone or with technical domain like Sheetmetal, Jigs & Fixture Design, Product Design, Casting Design, Weldment Structure Design.
• Siemens NX CAD alone or with technical domain like Sheetmetal, Jigs & Fixture Design, Product Design, Casting Design, Weldment Structure Design.
• Creo Parametric CAD alone or with technical domain like Sheetmetal, Jigs & Fixture Design, Product Design, Casting Design, Weldment Structure Design.
• AutoCAD Mechanical CAD – 2D & 3D.
• Any customized specific domain topics like Jigs & Fixture Design, Product Design, Casting Design, Weldment Structure Design without any CAD included.
• Any other specific areas like Bearing Selection, GD&T application, Pulley & Belt design, Gear Design, Gearbox Design & Calculation, Spring Selection, Pneumatic & Hydraulic parts selection, Material Selections etc.