Rachit

Experience

• Freelance Mechanical Design & Simulation Engineer Pro camper India Pvt. ltd · Freelance Feb 2025 – Aug 2025 6 mos Noida, UP, India At Pro Camper India, I spearheaded innovative engineering design solutions for caravan, campervan, and expedition vehicle projects—collaborating with domain expert Dhruv North and leading the technical efforts for multiple high-visibility builds.
  
  Key Responsibilities and Achievements:
  
  Tata Ultra T7 Expedition Vehicle: Engineered a lightweight cantilever sleeping pod (approx. 125 kg) with aerodynamic profiling above the driver’s cabin, creating an innovative accommodation solution for two people separate from the main family cabin. This required advanced structural analysis and fabrication techniques to maintain integrity and minimize weight impact.
  
  Mahindra Veero Camper Van Prototype: Developed and optimized a 350 kg aluminum structural body frame for Mahindra’s presentation, targeting a future 4x4 version. Emphasized modular design, weight reduction, and presentation readiness for corporate and client demos.
  
  Military Server/Telecom Vehicle (Indian Military Academy): Designed a modular server van with a reinforced roof capable of supporting up to 1000 kg, while keeping the total build weight to 400 kg. Focused on military-grade tolerances, adaptability for field deployment, and enhanced durability for service personnel.
  
  Advanced Structural & Sheet Metal Fabrication: Utilized sophisticated CAD methodologies to translate conceptual sketches into production-ready assemblies, meeting demanding standards for safety, modularity, and transportability.
  
  Collaboration & R&D: Partnered directly with experienced YouTubers and camper industry specialists to co-develop product concepts aligning with market trends, manufacturing feasibility, and end-user expectations.
  
  Software Skills Used: SolidWorks, AutoCAD; advanced fabrication planning, CAD modeling, and simulation for camper and vehicle systems.
• Design Engineer CFF Fluid Controls Ltd · Full-time Sep 2022 – Apr 2025 2 yrs 7 mos Khopoli, MH, India At CFF Fluid Control Ltd., I worked as a Design Engineer specializing in the design, testing, manufacturing, and documentation of advanced valve systems and pressure reduction panels for both defense and industrial clients, including the Indian Navy, GRSE, MDL, GSL, and DMDE.
  
  Key Responsibilities and Achievements:
  
  Valve & Fixture Design: Engineered gate, ball, butterfly, check, plug, foot, SDNR, and fire hydrant valves, as well as Body-in-White (BIW) fixtures and spring mechanisms. My work encompassed innovative valve designs for marine vehicles, submarines, and fire protection systems in defense applications.
  
  Flow and Structural Analysis: Conducted rigorous flow simulations and strength analysis to ensure product reliability and optimize performance to meet standards such as API 6D, ASME Section VIII, and B16.34, incorporating GD&T dimensioning as per ASME Y14.5.
  
  Manufacturing Support: Oversaw the complete process from 3D modeling and detailed fabrication drawing (GA, CS, PID) generation using SolidWorks and AutoCAD, to planning and coordinating with manufacturing and QA teams for successful prototyping, assembly, and testing.
  
  Cross-Functional Collaboration: Worked closely with engineering, QA, and project management teams to deliver high-quality valves according to client specifications, ensuring timely delivery and adherence to industry standards.
  
  Client Projects: Led and supported major design and development initiatives for defense marine clients, delivering panel systems and valves to Indian Navy, GRSE Garden Reach Shipbuilders, MDL Mazgaon Dock, GSL Goa Shipyard, and DMDE Defence Machinery Design Establishment.
  
  Documentation & Quality Compliance: Generated comprehensive technical documentation, design drawings, test plans, and process flows. Maintained strict compliance with military and fire safety standards throughout the product lifecycle.
  
  Industry Impact: My designs contributed to significant operational improvements in defense marine vehicles and fire protection systems, reflecting a strong commitment to safety, reliability, and technical excellence.
  
  Software Skills Used: SolidWorks, AutoCAD, CATIA, Creo; advanced drafting, 3D modeling, and simulation tools; knowledge of CNC machining and fabrication practices.
• R&D Design Engineer Tri-Parulex Fire Fighters · Full-time May 2024 – Nov 2024 6 mos Ghaziabad, UP, India At Tri-Parulex Fire Protection Systems, I served as an R&D Design Engineer focused on advanced fire suppression and safety solutions for industrial and critical infrastructure applications.
  
  Key Responsibilities and Achievements:
  
  Reverse Engineering & Valve Development: Led reverse-engineering efforts on imported German pressure-regulating valves, translating them into indigenous solutions ranging from 15 bar to 250 bar systems. Delivered technical drawings, process plans, and machining documentation for new product lines and system upgrades.
  
  Fire Safety System Design: Developed Nitrogen Injection Fire Protection Systems (NIFPS) and CO₂-based fire suppression solutions, including pressure regulators adapted for larger tank capacities (from 65L to 110L, capable of withstanding pressures above 400 bar).
  
  Innovative Product Engineering: Designed foam-based fire suppression valves and portable, pressure-regulated tanks (15–25 bar), supporting both solenoid-activated and manual hammer arrangements. Prototyped a 150 bar pressure-regulating valve utilizing both casting and forging processes.
  
  Enclosure & Fabrication Design: Engineered durable sheet metal enclosures for system integration with IP67 and IP55 ingress protection, ensuring safety and regulatory compliance in harsh industrial environments.
  
  Material and Quality Control: Managed selection and inspection of critical materials for high-pressure and fire safety standards, ensuring each design met international (ASME B16.34, BS4501) fire safety and pressure vessel codes.
  
  System Integration & Testing: Oversaw detailed system integration, assembly, testing, and analysis to validate performance and reliability of developed fire suppression systems in real-world operating conditions.
  
  Documentation & Collaboration: Delivered accurate, industry-standard drawings and BOMs, collaborating closely with senior engineers and production teams to oversee the full product lifecycle from concept to field deployment.
  
  Software & Technical Skills: SolidWorks, AutoCAD, advanced sheet-metal fabrication, FEA-driven design validation, pressure vessel system integration, and knowledge of fire safety regulatory frameworks.
• Trainee Design Engineer Central Tool Room & Training Centre · Full-time Aug 2021 – Aug 2022 1 yrs Bhubaneswar, OD, India At DRDO Cell (CTTC Bhubaneswar), I contributed extensively as an On-Job Trainee Design Engineer to strategic defense research and development projects, working with line replacement units (LRUs) and fuel booster systems for advanced platforms like the Tejas Aircraft under the DRDO-TDF program.
  
  Key Responsibilities and Achievements:
  
  3D Modeling & 2D Drafting: Created detailed 3D models and 2D drawings for mission-critical components and assemblies using SolidWorks, AutoCAD, CATIA, and Creo. Ensured all representations adhered to defense and engineering standards, with a strong emphasis on accuracy, manufacturability, and reliability.
  
  Process & Production Planning: Developed comprehensive process plans and production documentation for the fabrication and assembly of aerospace LRUs, mapping out machining, assembly, and QC steps required to meet stringent defense quality protocols.
  
  Structural & Reliability Analysis: Conducted simulation-driven structural and model reliability analysis of components under various operational loads and flight conditions. Focused on maximizing performance and safety for applications in fuel booster systems and line replacement units for aircraft and armored defense vehicles.
  
  Quality Assurance (QA) & Documentation: Formulated QA plans, maintained meticulous records, and supported inspection protocols to ensure delivery of high-quality design outputs capable of withstanding critical defense applications.
  
  Interdisciplinary Collaboration: Coordinated with cross-disciplinary teams including R&D engineers, manufacturing, and QA to synchronize design outputs with testing, prototyping, and functional validation at all stages.
  
  Exposure to Full Project Lifecycle: Actively participated in the end-to-end lifecycle of components—from initial CAD/CAM conceptualization to prototype manufacturing and functional trials—demonstrating a robust understanding of how complex defense and aerospace solutions transition from design to real-world operation.
  
  Highlighted Project:
  
  Tejas Aircraft Fuel Booster System: Supported the design and process planning for fuel booster systems integrated in India's LCA Tejas, ensuring components met operational reliability in varied flight conditions (vertical/in-vertical). Focused on designs that enabled rapid replacement and minimized aircraft downtime—key to modern defense logistics.
  
  Software Skills Used: SolidWorks, CATIA, Creo, AutoCAD, Ansys (for FEA), supported by knowledge in CNC machining and advanced manufacturing techniques.