Sanjay K.
Engineering Design & Validation Consultant for Industrial Systems
Chennai,
India
Global rank:
4,110
/
120,889
Skill pts: 10
About
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
-----------------------------------------------
📩 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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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.
----------------------------------------------
🔧 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
----------------------------------------------
🛠 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.
----------------------------------------------
🏭 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)
----------------------------------------------
📊 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
-----------------------------------------------
📩 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.
----------------------------------------------
Portfolio
Experience
-
Industrial Design Engineer
Private · Freelance
Jan 2025 –
Jun 2025
5 mos
Pune, MH, India
As a Growing Professional who’s building an unshakeable foundation in engineering and technology, I’ve honed my skills in various disciplines and unconventional ways and built an enormous set of skill sets over the last half a decade. With years of experience in Product Design & Development; transforming complex engineering problems into manufacturable and deployable technological solutions that meet the demands just right and also align with the latest engineering design standards is and has been our forte.
Being an Industrial Design Engineer & Systems Integrator specializing in Product Design & Development for Multiple Engineering sectors, I provide end-to-end design and engineering support that helps businesses move from concept to production with confidence. From design thinking workshops and ideation sessions to 3D modelling, simulation, and optimization, I ensure every stage of development is creative, technically sound, and manufacturable. Whether it’s reverse engineering an existing product, validating a new concept, or streamlining design for manufacturing, you get solutions that are practical, efficient, and aligned with industry standards — so your product is not only innovative but also ready for real-world success.
Projects I've worked;
- Reverse Engineering Parametric Modelling : Surface Re-construction & Refinement for 3D Printing.
- FEA Optimization : Microelectronics Cooling System; dropped Temps. of a 100W TPP system by 25%.
- Product Design & Development : FPV Video Capture Drone ~ Complete Product Development. -
Senior Design Engineer
Defense industry · Full-time
Dec 2022 –
Dec 2024
2 yrs
Pune, MH, India
Responsible for the Complete Design & Integration of non-ordinance-based systems such as recovery loader cranes, portable & deployable bridges, and Auxiliary power units on HMV vehicles. Excellent track record for Product Design & Manufacturing. Received special appreciation for 3D modelling and conceptual development of prototype ideation.
R&D Design and manufacturing of Loader material handling systems. Manufacturing Design - Fixed Boom and Knuckle Boom Cranes. Fundamental Standards - IS, EN, and ISO Standards for System Design & Development.
Design and Study of Sheet metal & Carbon Composite (UD 700) material components. Verbal Communication between vendors, suppliers and production team for Product Manufacturing.
Achievements and Key Highlights:
Fixed Boom Crane - Concept Design Technically qualified for a Government Tender. 2% Increase in Structural efficiency & maneuverability using High-strength steel.
3% Increase in Hydraulic cylinder efficiency by optimizing loads at cylinder joints. Introduction to unique Hydraulic Rotary Joint mechanism for 360° Slewing of the Crane.
Skills Gained: Materials & Metallurgy - Sheet metal, Block metal, Composite Materials, Conceptual 3D Modelling, Sheet metal Design, Hydraulic Circuit basics, -
Design Engineer
Stellantis · Full-time
Jan 2022 –
Jul 2022
6 mos
Chennai, TN, India
Key Roles & Responsibilities performed throughout Employment.: - Completed training courses on various procedures in Vehicle Design organized by the Company.
- Designed Rear Cover Caps of Industrial Van Tail Light - Reduced weight by close to 2%.
- Front Fascia Bracket and Side Foot bar - Sped up modelling time by 15% by Design Optimization.
- Practiced Injection flow simulation process. Reduced 0.5% material wastage in Partition Draft parts.
- Studied Additional Procedures for Plastic Injection Molding including drafting, tooling, and creating part moldings.
- Completed a Design task within 2 weeks during the initial days of industrial training.
Skills Gained: Plastic Parts Design, Exterior Trims, Exterior Hard Trims, BIW Fixtures & Brackets, Sheet Metal & Plastic Integration Methods, Siemens NX, PLM and Teamcenter Client.
Education
- Symbiosis International University MBA, Finance, 8.00 2024 – 2026
- Symbiosis Institute of Technology B.Tech, Mechacnical Engineering, 7.35 2018 – 2022 Activities and Societies: null
Other experience
-
Research conducted at university
Research on Numerical simulation of heat transfer and pressure drop characteristics for non-Newtonian fluids in a microchannel
Optimized a pre-designed microchannel to improve its performance and efficiency. Prepared a design with Calculations using a well-optimized geometry with increased thermal efficiency. Analyzed micro channel's performance using non-Newtonian fluid as a source using CFD simulations with ANSYS. Conducted virtual studies to understand its advantage as a replacement under various applications and optimized the solution. Compiled all research data into a research paper for publication under a certification Authority.
Licenses & Certifications
- Simulink Onramp Feb 2021 – Present
- MATLAB Onramp Feb 2021 – Present
- Manufacturing Process with Autodesk Fusion 360 Nov 2020 – Present See credential
- Digital Manufacturing & Design Oct 2020 – Present See credential
Stats
0 followers, 0 following
Age: 25
Joined: December 6, 2025
Last seen: January 19, 2026
Area of Expertise
Industrial Design Services
Concept Design
Engineering Design
Mechanical Engineering
Structural Engineering
Tool Design Services
Reverse Engineering
FEA Finite Element Analysis
HVAC Design Services
Rapid Prototyping Services
3D Models of Machine Parts
Design Engineering Services
Assembly Modeling Services
Prototype Design Engineering
Mechanical Design Services
Computational Fluid Dynamics
3D Product Modeling
Product Engineering Services
Design for Assembly Services
3D Scan to CAD Service
Languages
English Full professional proficiency
Location
Chennai, India