Apr 2024 – Sep 2025 · 1 yr 5 mos

• Lead Design Engineer for Halo Gen 2 [Optimization for cost, scale, assembly and New Features add on].
• Conceptualized and developed new side and jaw pad within the helmet to enable smarter packaging of wear detection sensors, audio speakers and mic.
• Solved one of the critical issue of Gen1 by doing the above. The new speaker mount also enabled improved egress and ingress and designed in a way which provides Spring back, hence allowing auto speaker adjustment within the helmet.
• Redesigned the speaker locking mechanism which improves the locking force by 80% and also improved acoustics by 25%. The new locking mechanism allowed sealing of the speaker's front and rear sides and eventually avoiding the intermixing of the parasitic waves emerging from rear side of speakers with the front usable sound waves of the speaker. The result was also a better perceived sound quality, better mid range and better sound channeling towards the user's ear.
• Tweaked the sensor snap locking design to improve the pull force requirements by 25% while also improving the overall reliability by introducing flexing points to minimize concentrated stress concentration.
• Redesigned the mic mount to improve DFA and also added wire routing and clamping points. Also, improved the BOM cost by around 10%
• Future tech PoC Projects: Worked on an onboard and offboard cooling capable Battery Pack concept with top and bottom cold plate stack to enable super fast charging and discharging. The intent of the thermal design was to keep the cell temperature upto 3±2 degrees Celsius.
• The coldplate also acted as the BMS mount with bottom facing MOSFET cooling.
• Future feature addition (yet to launch) integration and PoC without doing a major redesign of the Gen1 Halo Bit.
• Worked on Auto headlamp orientation control to ensure ride height changes don't impact the light throw onto the road and eventually the visibility. 2 patent filings on the same.
• Future Package Protection,Tech Integration PoC for Halo Bit.

Sep 2022 – Nov 2025 · 3 yrs 2 mos

• Lead hardware packaging & mechanical design engineer for Smart Helmet Ecosystem [Halo full face , Halo bit half face Smart helmets , Wireless charger, Multi purpose charger, Onboard Power adapter and the Power adapter cap].
• Full stack development including architecture definition, mechanical, electromechanical integration and mechanism design.
• Lead Development Engineer of inhouse patented 2 way electromechanical lock set.

Mar 2022 – Sep 2022 · 6 mos

• Worked on the Ather Transmission System. Lead role in deriving the teeth profile of all three pulleys[Motor, Intermediate and Wheel]. Proposed multiple cost reduction ideas and design concepts which could potentially be used.
• Worked on a test setup to understand the belt flutter at different operating conditions.

Aug 2021 – Mar 2022 · 7 mos

• Worked on the development of a new brake system. The work involved the packaging, stackups, interaction checks, cost reduction ideas, bundy tube exploration, disc-drum exploration, design calculations, bracket design and the brake system routing.
• Developed the new alternate full brake system with Tier 2 Supplier well before the time.

Feb 2020 – Aug 2021 · 1 yr 6 mos

• Worked on interaction checks, virtual assy checks, fitment and tolerance stackups for all the new development parts, assy and impacted child parts if any. Worked on managing the releases, new part creation , variant management and the overall release cycles.

Dec 2019 – Feb 2020 · 2 mos

• Worked on Speaker assy and redesigned the overall stack to resolve the in field bugs. The rubber gasket, the insulation sheet/dust cover and the plastic enclosure were the components that were worked upon.
• The part is successfully running in the existing models without any bugs.

Jun 2019 – Dec 2019 · 6 mos

• Mostly worked on sustenance projects. Ather 450 and 340 were launched just before I joined and being a new product, it had certain bugs and issues and my role was to take care of the field bugs, take care of the gaps with engineers and to finally resolve them. A super important year with loads of ground work and learning.

Sep 2018 – Feb 2019 · 5 mos

• One of the last automobile projects that I worked on. We called it the 'Zeus'. The objective of working on this car was to participate in the very famous competition called 'Shell Eco Marathon' , which was happening in India for the very first time.
• Also, it was the last year of my college, so wanted to work on something new,
• Since, we had very limited time we knew we will not be doing something very very radical or different, but yes we will conceptualise, develop and test whatever we did.
• 1 .We decided to work on the frame made of chromoly tubes, since we already had the know how.
• 2. All three disc brakes actuated by the wire based mechanisms.(since, mileage was the aim, speed was limited).
• 3. Drivers position was kept very low to keep the Centre of gravity as low as possible.
• 4. The most challenging part was the engine calibration, since we had to convert the carbureted engine into a fuel injected one. Honestly, wanted to work on the Honda's 50cc grasscutter engine but since we had time and resource limitations, we went with Bajaj platina 100 engine.
• Developing the intake was interesting , but marrying it with the Fi system was quite complex since the concept of calibration was very new. Started the calibration part and managed to do so, here are the learnings :
• a. In order to start the engine, you need a rich mixture or atleast momentarily you need a multiplication factor for fuel injection.
• b. Temperature as always, has the dominant role. Until the engine gets to its sweet spot(>90 degrees), you cannot play around the fuel injection timing.
• c. Spark advance and delay can totally alter the amount of vibartion and rpm your engine has.
• d. Initially the engine needed the 2.5ms pwm fuel injection, but after it reaches the right temperature and settings,it could sustain around 0.7 ms pwm fuel injection.
• e. At a higher temp zone, like Chennai running too rich mixture for starting would not help.
• 5. The engine was positioned in the rear in order to have proper wt.dist

Apr 2018 – Mar 2019 · 11 mos

Oct 2017 – May 2019 · 1 yr 7 mos

Oct 2017 – Apr 2018 · 6 mos

• The solar car project, Project Infinity

Mar 2017 – Jan 2018 · 10 mos

Mar 2016 – Apr 2017 · 1 yr 1 mo

• It was in my 1st year of engineering, when the idea of making a prototype and concept solar car named Infinity. Me along with other 1st year and other folks from 2nd, 3rd and 4th year collaborated and developded a solar car which was capable of doing around 100 kms of running on a single charge.
• I conceptualised it and was responsible for selection of motor, battery, drivetrain and the rest of vehicle Integration.
• With the help of university support, the full project was developed within 6 months of timeframe.
• It was equipped with a RX 100 gearbox that would allow different transmission ratios at different operating conditions.
• Powered from the 350 watts of solar panels spread across the vehicle and 48 volts of battery pack and motor architecture, it was my 2nd project as an engineering graduate student and 1st as a Captain and Technical Lead.

Sep 2015 – Sep 2016 · 1 yr

• Lead Powertrain Integrator & Architect of Effi Car Project. A battery powered 4 wheeled concept car with a payload capacity of 300 kgs and 2 passenger capability.
• I was responsible for selecting the motor, battery capacity, battery type, integration and the cooling system design of the overall project.
• Also, I looked at the overall design report, chassis design and the harness.

Aug 2015 – Mar 2016 · 7 mos

• In my 1st year of engineering, I joined my university's newly formed team named GEU Motorsports.
• Filled with passion and learning attitude, I seriously wanted to see and learn the actual applications of the engineering and that fuelled me to join in the team, whatever be the position.
• Joined just to assist my seniors with any support they require, I started my motorsport and engineering there.
• A year full of learning, I saw the development of Pastiche, a formula student car aimed at competing in the Formula student india event which was held in BIC, Noida.
• I witnessed the conceptualisation, cad modelling , calculations, cfd analysis, fea analysis, meshing, manufacturing, marketing and the documentation part.
• Super grateful to my seniors for the opportunity.