Jan 2025 – Present · 1 yr 5 mos

• Led design and development of multiple defense and automotive projects involving ARMOX 440T and 500T ballistic steel. Engineered FRP composite sandwich structures for an amphibious vehicle hull and tested them for weight optimization and impact resistance. Executed reverse engineering of critical tank subsystems, including control arms, CV joints, break disk, and connecting rods, to support system reconfiguration and lifecycle extension. Performed structural and fatigue analysis using ANSYS and Creo Simulate to validate load-bearing capability under extreme operating conditions. Collaborated with manufacturing and materials teams to optimize weld geometry and joint stiffness for improved structural integrity. Managed PLM documentation, revision control, and BOM tracking for defense-grade projects.

Jun 2024 – Jan 2025 · 7 mos · Bengaluru, Karnataka, India · On-site

• I work on the design and development of precision electromechanical connectors and interconnect systems used in advanced technology equipment. My role involves detailed evaluation of materials, surface finishes, plating, sealing methods, and mechanical design to ensure high reliability in demanding environments.
• My work includes development and analysis of connector solutions such as circular connectors (MIL-DTL-5015 type), high-density signal connectors, power connectors, RF connectors, and sensor interface connectors used in complex electromechanical systems. I conduct evaluation of material compatibility, plating performance, mechanical integrity, and environmental testing in accordance with international engineering standards including MIL, ANSI, ASTM, EIA, and ISO.
• Through new product development activities, I contribute to the design and validation of high-precision interconnect components supporting systems that require reliable power, signal, and data transmission in industrial and high-technology applications.

Jun 2024 – Jan 2025 · 7 mos

• Designed and developed MIL-5015, Mighty Mouse, and MIL-DTL-83723 connectors from concept to production. Created 3D CAD models, tolerance stack-ups, and detailed drawings in SolidWorks ensuring MIL compliance. Conducted structural and modal FEA in ANSYS to evaluate fatigue performance under vibration and shock conditions. Utilized 3D printing for rapid prototyping and assembly validation.

Dec 2023 – Feb 2024 · 2 mos

Dec 2023 – Feb 2024 · 2 mos

• Delivered design and FEA projects for clients across automotive, consumer, and industrial domains. Developed and optimized plastic injection-molded parts for manufacturability and assembly. Conducted design and structural analysis of holding structures using SolidWorks and ANSYS, including load, deformation, and buckling studies.

Aug 2023 – May 2024 · 9 mos · India · On-site

• Conducted research on Shape Memory Alloy (SMA) based mechanical joints for high-reliability engineering applications. Performed finite element structural analysis using ANSYS to evaluate stress distribution, deformation behaviour, and structural performance. Designed and evaluated precision mechanical components and assemblies using CAD tools. Investigated thermal–mechanical behaviour of advanced materials under operational loading conditions. Supported prototype development and experimental validation to assess joint performance and contributed to technical documentation leading to a conference publication at NIT Warangal.

Aug 2023 – May 2024 · 9 mos

• Conducted research on shape memory alloy joints for aerospace structures, published findings at NIT Warangal. Performed static structural, modal, and optimization analysis in ANSYS Workbench. Proposed actuator replacement designs improving stiffness-to-weight ratios in aerospace assemblies.