I'm Sanjay Karthik, Mechanical Design and Simulation Engineer with experience in delivering standards-compliant, manufacturable mechanical systems for clients across automotive, aerospace, heavy machi...
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I'm Sanjay Karthik, Mechanical Design and Simulation Engineer with experience in delivering standards-compliant, manufacturable mechanical systems for clients across automotive, aerospace, heavy machinery, energy, and industrial sectors.
I provide end-to-end mechanical design, optimization, and validation support for engineering-driven organizations developing complex industrial systems. My work spans concept development, structural and hydraulic design calculations, FEA-driven optimization, and design-for-manufacturing, ensuring products are technically sound, compliant with EN / ISO / IS standards, and ready for production before physical prototyping.
By collaborating with me, you gain a design partner who delivers validated engineering decisions—not just CAD models. Clients benefit from optimized structures, documented analysis, compliance-ready designs, and clear technical justification that reduces development risk, shortens design cycles, and supports confident progression to manufacturing.
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🔧 What I Help You Achieve
🔹 Validate engineering concepts before costly prototyping and testing
🔹 Reduce structural weight while maintaining required safety margins
🔹 Ensure compliance with ISO, EN, IS, DIN, and MIL engineering standards
🔹 Improve manufacturability, reliability, and overall system efficiency
🔹 Reduce physical prototyping through virtual simulation and engineering calculations
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🛠 Core Engineering Design & Development Services
✅ Engineering Design Optimization & Validation:
Structural, thermal, fluid, and dynamic analysis to improve performance, reduce weight, and ensure compliance with global standards.
✅ Concept-to-Production Mechanical System Design:
End-to-end development of mechanical and electro-mechanical systems from early concept through manufacturing readiness.
✅ Design for Manufacturing & Production Feasibility (DFM/DFA):
Manufacturing-focused design reviews, detailing, and documentation aligned with real production and vendor constraints.
✅ Reverse Engineering & Parametric Product Development:
Intelligent reconstruction, improvement, and parametrization of existing products for redesign, localization, or cost reduction.
✅ Advanced Simulation & Virtual Testing:
FEA, CFD, NVH, and Multibody Dynamics (MBD) simulations to validate system behavior and eliminate physical testing risk.
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🏭 Multi-Industry Experience
🔸 Automotive subsystems and load-bearing structural components
🔸 Aerospace ground support and auxiliary equipment
🔸 Heavy machinery and material handling systems
🔸 Energy, power, and thermal engineering systems
🔸 Industrial and defense auxiliary equipment (non-ordinance)
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📊 Why Choose to Work With Me
🔸 Engineering-first decisions backed by calculations, simulation, and standards
🔸 Compliance-ready documentation suitable for design reviews and certification
🔸 Manufacturing-aware designs that work beyond CAD and simulation
🔸 Clear, direct communication with no ambiguity or surprises
🔸 Risk-focused approach that reduces redesign, delays, and cost overruns
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📩 Next Steps
If you’re seeking a reliable engineering partner to support design optimization, validation, or production readiness, feel free to get in touch to discuss your project scope and technical requirements. I will assess your objectives and outline a clear, structured approach aligned with your standards, timelines, and manufacturing constraints.
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