Shashanka H.

Experience

• Design engineer Cyient Ltd · Full-time Dec 2025 – Present 8 mos Bengaluru, KA, India •Designing the High Voltage Power Distribution Unit (HVPDU) for Air Taxi and eVTOL applications, focusing on hardware architecture, packaging layout, electronic component placement, and compliance with customer and product development requirements.
  •Designed and developed DC–DC converter enclosures using sheet metal and machined aluminium components, considering thermal management, EMI/EMC, electrical safety clearances, manufacturability, and cost optimization.
  •Led the mechanical design of COM Radio assemblies, covering PCB integration, connector and switch packaging, power amplifier placement, heat sink optimization, and enclosure development for thermal and structural performance.
  •Designed plastic injection-moulded enclosures for compact electronic products, applying DFM principles such as uniform wall thickness, draft angles, ribs, bosses, fillets, and parting line considerations.
  •Translated functional, packaging, and customer requirements into detailed 3D CAD models, 2D engineering drawings, and BOMs using SolidWorks.
  •Supported prototype development, fitment validation, design refinement, and engineering release activities through design reviews and iterative design improvements.
  •Prepared and maintained GD&T-based drawings, technical documentation, and controlled engineering data to support product release and manufacturing readiness.
  •Participated in tolerance stack-up analysis, design reviews, DFMEA discussions, and cost optimization activities with global engineering, manufacturing, and procurement teams.
  •Coordinated with suppliers, manufacturing teams, and internal stakeholders to address design feasibility, manufacturability concerns, and engineering changes.
  •Supported Engineering Change Requests (ECRs) and Engineering Change Orders
• Design Engiineer (Mechaanical) PRERANA ENGINEERING WORKS · Full-time Jun 2023 – Dec 2025 2 yrs 6 mos KA, India •Completed end-to-end industrial gearbox design, including CAD modelling, detail drawing preparation, assembly verification, and supplier coordination for bearing selection.
  •Independently designed and developed three teach pendant prototypes from concept to assembly, including compact housing design, electronics integration, ergonomic improvement, and prototype validation.
  •Designed and delivered 30+ machining fixtures, validating performance on the shop floor and supporting manufacturing with functional and practical design solutions.
  •Disassembled, reverse-engineered, modeled, and reassembled a 6-axis industrial robot, including integration of alternate motors and development of a custom electrical cabinet.
  •Designed and fabricated sheet metal electrical cabinets for robotic controller systems, ensuring proper component layout, ventilation, grounding, serviceability, and manufacturability.
  •Supported automation and robotic system development, including pick-and-place setups, pneumatic integration, gripper/jaw selection, gripper plate design, and simulation-based motion validation.
  •Developed special tooling and work-holding solutions such as angle blocks, jaws, and custom cutting tools for precision machining applications.
  •Prepared 3D CAD models, manufacturing drawings, and technical documentation for spindles, housings, robotic accessories, and custom machine components.
  •Worked closely with shop-floor teams, suppliers, and internal stakeholders to resolve manufacturing, assembly, and fitment issues, improving practicality and design robustness.
  •Supported R&D and prototype development activities, contributing to iterative design improvements and manufacturable product solutions.