Mridhul D.

Experience

• Pole Crash Test Simulation (Automotive Safety) Client Work · Freelance Nov 2025 – Jan 2026 2 mos Germany The project involved simulating a pole crash test in LS Dyna to evaluate structural behaviour under both frontal and side impacts, with particular focus on the pole vehicle interaction. The objective was to benchmark performance against Euro NCAP style requirements and provide reinforcement strategies to improve safety compliance.
  
  Detailed CAD models of the vehicle structure and pole barrier were developed in SolidWorks and prepared for explicit crash simulation, with calibrated material definitions, contact models, and boundary conditions replicating regulatory standards.
  
  Results showed intrusion depths of 210-220 mm, peak occupant loading of 28 g, and total energy absorption above 65 kJ. Acceleration time histories confirmed controlled load transfer throughout the event, while quantified load paths revealed critical stress channels in the side sill and floorpan. Deformation occurred within 61 ms, highlighting localized failures and guiding targeted reinforcement concepts.
• Pump Impeller Design & Hydraulic Optimization Government backed energy project · Freelance Jul 2025 – Oct 2025 3 mos Canada Commissioned within a government backed energy program, this project delivered a centrifugal pump impeller for large scale pumping operations. The mandate was to increase efficiency and reliability while ensuring the design remained practical for industrial manufacturing and long term operation.
  
  The impeller was developed in SolidWorks with multiple design iterations refining blade geometry and hub configuration. Performance was validated through CFD simulations in Ansys Fluent and StarCCM+, with a focus on reducing hydraulic losses, improving velocity balance, and extending cavitation resistance under demanding duty cycles.
  
  The optimized design achieved a 14% efficiency improvement, a 20% reduction in hydraulic losses, and a 30% improvement in flow uniformity, while extending cavitation margin by 12% compared to baseline. These results directly supported project targets for lower energy consumption and stable long term operation.
• Intake Manifold CFD Optimization (Dual Inlet) Independent European Motorsport Team · Freelance Mar 2025 – Jun 2025 3 mos Germany This project addressed uneven flow distribution in a dual inlet intake manifold intended for high-performance automotive applications.
  
  The goal: deliver consistent air fuel balance across all cylinders while minimizing pressure losses.
  
  A baseline model was developed in SolidWorks and iteratively refined. CFD simulations in StarCCM+ evaluated velocity distribution, pressure drop, and turbulence intensity across design variants. Runner geometry and inlet angles were systematically optimized to achieve uniform flow delivery.
  
  The optimized design achieved a 4× reduction in velocity scatter, reduced pressure drop to 236 Pa, and secured
• Propeller Design & Mixing Optimization Government Backed energy project · Freelance Nov 2024 – Feb 2025 3 mos Canada Within a government backed energy program, a 14 inch Michigan Wheel DJ 355 propeller was redesigned to transform industrial scale mixing operations. The challenge was clear: eliminate stagnant zones that undermined process reliability and reduce escalating energy costs in continuous use tanks.
  
  Using SolidWorks for CAD and StarCCM+ with MRF for simulation, the propeller underwent multiple design refinements. The final configuration achieved a 100% elimination of dead zones, a 12–15% reduction in energy input per cycle, and a 312 Pa lower pressure drop versus baseline.
  
  This result established a new benchmark for energy efficient industrial mixing demonstrating how precision design and CFD driven optimization can directly deliver cost savings and operational resilience. The engagement concluded with deployment ready CAD assemblies, CFD validation reports, and a full optimization dossier for scale up.
• Suspension & Chassis FEA (Off-Road Vehicle) Client (Motorsports) · Freelance Jun 2024 – Oct 2024 4 mos Germany A motorsport client commissioned the complete design and validation of an off road ATV chassis and suspension system.
  
  The mandate: engineer a suspension capable of withstanding 2g braking, 2.5g cornering, and 3g bump impacts, while balancing stiffness with a competitive strength to weight ratio.
  
  The system was designed in SolidWorks, including chassis frame, suspension geometry, and mounting hardpoints. Structural validation was carried out in Ansys Workbench, where finite element analysis assessed stress distribution, deflection, and fatigue life under racing loads. Iterative refinements strengthened high stress regions without unnecessary weight penalties.
  
  The final configuration achieved a Factor of Safety above 2.3 across all critical load cases, eliminating structural weak points and ensuring reliability for competitive racing.
• Formula 1 Front Wing CFD Optimization Independent Project · Freelance Jun 2021 – Nov 2021 5 mos United Kingdom This independent motorsport R&D initiative set out to create a Formula 1 front wing aligned with 2022 FIA regulations, with a mandate to raise aerodynamic efficiency while ensuring flow stability across multiple racing conditions.
  
  The baseline geometry was established in SolidWorks and subjected to a structured CFD program in Siemens StarCCM+. Multiple design iterations explored flap profiles, chord ratios, and endplate refinements, with each cycle benchmarked against aerodynamic performance metrics.
  
  The optimized configuration achieved an 8% increase in downforce and a 312 Pa reduction in pressure loss versus baseline, while significantly improving flow attachment at high angles of attack. Deliverables included validated CAD models, CFD reports, and aerodynamic visualization data, presented in a format directly transferable to prototype development.