Sakthivel M.

Experience

• Senior Mechanical Design & Development Engineer VISIONTEK CONTROLS · Full-time Oct 2024 – Present 1 yrs 8 mos Coimbatore, TN, India Leading mechanical design and development of turnkey industrial
  automation systems and machine vision inspection solutions for
  leading automotive, manufacturing, and precision engineering clients
  across India and global markets.
  
  KEY RESPONSIBILITIES:
  • Design end-to-end automated inspection stations integrating vision
  systems, pneumatic actuators, sensors, and PLC-controlled mechanisms.
  • Develop production-ready 3D CAD models, GD&T-compliant manufacturing
  drawings, BOMs, and assembly documentation using SolidWorks PDM.
  • Lead cross-functional collaboration with electrical, software, and
  manufacturing teams for seamless machine integration, process
  validation, and assembly optimization.
  • Engineer custom test rigs for automotive components and data
  acquisition platforms streamlining diagnostics and validation.
  • Apply DFM/DFA principles, tolerance stack-up analysis, and material
  optimization for cost-effective, manufacturable designs.
  • Implement process standardization protocols across design
  workflows and quality control systems.
  
  KEY ACHIEVEMENTS:
  ✔ Contributed to 3,500+ successfully delivered automation projects
  enhancing efficiency and process control across diverse industries.
  ✔ Improved inspection accuracy by 35% through vision-integrated
  automated mechanisms.
  ✔ Boosted production efficiency by 30% via standardized assembly
  protocols.
  ✔ Reduced rework rates significantly by applying DFM/DFA principles
  to automation equipment and precision assemblies.
  
  TOOLS: SolidWorks | SolidWorks PDM | AutoCAD | GD&T (ASME Y14.5)
  | ISO 9001 | ISO 2768 | Vision Systems | Pneumatic Design
• Founder & Principal Design Engineer Sculptor CAD Solutions · Self-employed Jan 2024 – Present 2 yrs 5 mos Salem, TN, India Founder of Sculptor CAD Solutions — a UDYAM-registered Special
  Purpose Machine (SPM) manufacturing and CAD design consultancy
  serving precision manufacturing sectors across India and
  international markets.
  
  KEY RESPONSIBILITIES:
  • Established and lead a UDYAM-registered SPM manufacturing and
  CAD design consultancy serving Tamil Nadu's precision
  manufacturing sector and global freelance clients.
  • Design and deliver complete SPM solutions including: 2-Ton
  Vertical Press Machines, Tube Beading Machines, Wire Rope
  Cutting Machines, Hydraulic System Assemblies, and Precision
  Component Fixtures.
  • Provide remote and on-site freelance CAD design services using
  SolidWorks, CREO, CATIA, and AutoCAD for clients across India
  and worldwide.
  • Manage end-to-end project execution — from client consultation
  and conceptual design to final production-ready deliverables.
  • Ensure full ISO 9001 / ISO 2768 / ASME Y14.5 compliance across
  all engineering deliverables.
  • Maintain confidentiality through NDAs and deliver intellectual
  property protection for client projects.
  
  SERVICES OFFERED:
  ✔ Special Purpose Machine (SPM) Design & Manufacturing
  ✔ Jigs, Fixtures & Tooling Design
  ✔ Hydraulic & Pneumatic System Engineering
  ✔ Reverse Engineering & Legacy Drawing Conversion
  ✔ 3D Modeling, 2D Drafting & GD&T Documentation
  ✔ Sheet Metal & Weldment Design
  ✔ Product Design & Rapid Prototyping
  ✔ DFM/DFA Analysis & Manufacturing Support
  
  KEY PROJECTS DELIVERED:
  • 2-Ton Vertical Hydraulic Press Machine
  • Tube Beading Machine (Automation)
  • Wire Rope Cutting Machine
  • Hydraulic System Design & Assembly
  • Precision Machining Fixtures & Jigs
  
  TAGLINE: "Precision Engineered. Innovation Delivered."
  
  TOOLS: SolidWorks | CREO Parametric | AutoCAD | Fusion 360
  | GD&T (ASME Y14.5) | ISO 9001 | ISO 2768 | SolidWorks PDM
• NDT Inspector – Level II (MPI & Eddy Current) Vibrant NDT Services Pvt Ltd · Full-time Aug 2019 – Apr 2026 6 yrs 8 mos Chennai, TN, India Performed Non-Destructive Testing (NDT) inspections on critical
  industrial components ensuring quality compliance with international
  ASME and ASTM standards.
  
  KEY RESPONSIBILITIES:
  • Conducted Magnetic Particle Inspection (MPI) and Eddy Current
  Testing for surface and subsurface defect detection on
  manufactured components.
  • Prepared detailed inspection reports documenting test parameters,
  findings, and compliance status.
  • Supported defect identification and root-cause analysis to
  improve manufacturing reliability.
  • Maintained quality traceability records for high-volume production
  components.
  • Ensured strict adherence to ASME, ASTM, and ISO quality standards.
  
  KEY ACHIEVEMENTS:
  ✔ Maintained 100% quality traceability for 2,000+ inspected parts
  annually.
  ✔ Contributed to defect reduction programs through systematic
  inspection reporting.
  ✔ Certified NDT Level II — MPI & Eddy Current.
  
  TOOLS: MPI Testing | Eddy Current Testing | ASME Standards
  | ASTM Standards | Quality Documentation
• Mechanical Design Engineer | Manufacturing Process Head Foeburr Pvt Ltd · Full-time Jan 2024 – Sep 2024 8 mos Chennai, TN, India Progressed from Junior Design Engineer to Senior Design Engineer,
  and ultimately to Manufacturing Process Head — leading full-cycle
  design, development, and production of advanced deburring machines
  and Special Purpose Machinery (SPM) for high-precision metalworking
  industries.
  
  KEY RESPONSIBILITIES:
  • Designed and delivered 15+ customized deburring SPMs including:
  gear deburring machines for large spur gears, arm deburring
  machines, roller brush tufting machines, wire brush crimping
  fixtures, hydraulic bristle cutting machines, stir machines, and
  fully customized automation solutions.
  • Led full-cycle product development — from conceptual CAD modeling
  and engineering calculations to prototyping, material selection,
  iterative design refinement, and final design approval.
  • Generated complete manufacturing packages: GD&T drawings (ASME
  Y14.5 / ISO 2768), BOMs, process documentation, and assembly
  instructions.
  • Executed manufacturability studies, tolerance stack-up evaluations,
  and cost optimization analyses.
  • Developed reverse engineering workflows for legacy machine
  modifications and upgrades.
  • Drove R&D-led improvements in arm deburring and brush manufacturing
  technologies ensuring best-in-class quality and manufacturability.
  • Collaborated with machining, fabrication, and assembly teams to
  resolve production challenges and enhance process reliability.
  
  KEY ACHIEVEMENTS:
  ✔ Independently designed and delivered a complete gear deburring
  machine — encompassing all engineering, prototyping, and
  production phases.
  ✔ Reduced production cost by 20% through DFM-driven design and
  tolerance optimization.
  ✔ Cut engineering turnaround time by 25% via reverse engineering
  workflows.
  ✔ Promoted twice within tenure based on technical leadership and
  project delivery excellence.
  
  TOOLS: SolidWorks | AutoCAD | CREO Parametric | GD&T (ASME Y14.5)
  | ISO 2768 | Hydraulic & Pneumatic Design | Reverse Engineering
• CNC Programmer & Design Liaison Engineer Gishnu Gears Pvt Ltd · Contract Feb 2022 – Mar 2023 1 yrs 1 mos Coimbatore, TN, India Served as the critical bridge between CNC programming, design,
  and production teams — delivering precision machining solutions
  for high-tolerance gear manufacturing and industrial components.
  
  KEY RESPONSIBILITIES:
  • Programmed optimized G-Code and M-Code CNC machining strategies
  for precision components on multi-axis machining centers.
  • Designed custom machining fixtures and work-holding systems
  improving dimensional repeatability and setup efficiency.
  • Provided DFM feedback and machining feasibility input during
  the design phase to reduce production cycle time.
  • Conducted dimensional inspection and tolerance verification for
  critical components using precision measuring instruments.
  • Collaborated with design engineers to translate CAD models into
  shop-floor manufacturing realities.
  
  KEY ACHIEVEMENTS:
  ✔ Reduced material scrap by 22% through optimized CNC toolpath
  programming and cutting strategy refinement.
  ✔ Achieved ±0.02 mm dimensional accuracy on critical precision
  components.
  ✔ Improved production setup efficiency through standardized
  fixture design.
  ✔ Bridged design-to-manufacturing gaps reducing engineering
  iterations and production delays.
  
  TOOLS: CNC Programming (G/M-Code) | SolidWorks | AutoCAD
  | GD&T | Precision Metrology | Fixture Design