Sanjay K.
Mechanical Design & Validation Engineer | Product Design & Development
Chennai,
India
Global rank:
4,711
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136,727
Skill pts: 10
About
Mechanical Design Engineer with 3+ years of experience specializing in product design & development, simulation, validation and optimization of industrial systems.
I help engineering teams develop manufacturable, production-ready solutions by improving performance, reducing redesign cycles, and minimizing prototyping through engineering calculations, simulation-driven optimization, and practical design methods focused on manufacturing feasibility, reliability, and reduced development risk.
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🔧 What I Help You Achieve
✅ Validate concepts before costly prototyping and testing
✅ Optimize weight without compromising safety or performance
✅ Ensure compliance with ISO, EN, IS, DIN, MIL standards
✅ Improve manufacturability, reliability, and system efficiency
✅ Reduce development time using simulation and engineering analysis
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🛠 Core Engineering Design & Development Services
🔹 Design Optimization: Improve performance, weight, and compliance
🔹 End-to-End Design: From concept to production-ready systems
🔹 DFM/DFA: Design for efficient, manufacturable production
🔹 Reverse Engineering: Re-design for cost reduction and improvement
🔹 Advanced Simulation: FEA, CFD, NVH, and MBD validation
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🏭 What systems do I design and validate?
🔸 Load-bearing structural and frame-based mechanical systems
🔸 Heavy-duty mechanical assemblies and machine structures
🔸 Precision-engineered components for dynamic loading applications
🔸 Equipment-level design involving actuation and support systems
🔸 Structural systems requiring high reliability and safety margins
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📊 Why Choose to Work With Me
✔ Decisions backed by engineering calculations, simulation, and standards compliance
✔ Design documentation ready for review, validation, and certification workflows
✔ Manufacturing-focused approach that ensures real-world feasibility beyond CAD
✔ Clear, structured communication with no ambiguity in execution
✔ Risk-driven engineering that reduces redesigns, delays, and cost overruns
------------------------------------------------
📩 What are you looking to build or optimize?
If you need support with design optimization, validation, or production-ready engineering, feel free to reach out with your project details. I’ll review your requirements and outline a structured approach aligned with your technical goals, standards, timelines, and manufacturing constraints.
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I help engineering teams develop manufacturable, production-ready solutions by improving performance, reducing redesign cycles, and minimizing prototyping through engineering calculations, simulation-driven optimization, and practical design methods focused on manufacturing feasibility, reliability, and reduced development risk.
------------------------------------------------
🔧 What I Help You Achieve
✅ Validate concepts before costly prototyping and testing
✅ Optimize weight without compromising safety or performance
✅ Ensure compliance with ISO, EN, IS, DIN, MIL standards
✅ Improve manufacturability, reliability, and system efficiency
✅ Reduce development time using simulation and engineering analysis
------------------------------------------------
🛠 Core Engineering Design & Development Services
🔹 Design Optimization: Improve performance, weight, and compliance
🔹 End-to-End Design: From concept to production-ready systems
🔹 DFM/DFA: Design for efficient, manufacturable production
🔹 Reverse Engineering: Re-design for cost reduction and improvement
🔹 Advanced Simulation: FEA, CFD, NVH, and MBD validation
------------------------------------------------
🏭 What systems do I design and validate?
🔸 Load-bearing structural and frame-based mechanical systems
🔸 Heavy-duty mechanical assemblies and machine structures
🔸 Precision-engineered components for dynamic loading applications
🔸 Equipment-level design involving actuation and support systems
🔸 Structural systems requiring high reliability and safety margins
------------------------------------------------
📊 Why Choose to Work With Me
✔ Decisions backed by engineering calculations, simulation, and standards compliance
✔ Design documentation ready for review, validation, and certification workflows
✔ Manufacturing-focused approach that ensures real-world feasibility beyond CAD
✔ Clear, structured communication with no ambiguity in execution
✔ Risk-driven engineering that reduces redesigns, delays, and cost overruns
------------------------------------------------
📩 What are you looking to build or optimize?
If you need support with design optimization, validation, or production-ready engineering, feel free to reach out with your project details. I’ll review your requirements and outline a structured approach aligned with your technical goals, standards, timelines, and manufacturing constraints.
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Portfolio
Service offers
Experience
-
Industrial Design Engineer
Private · Freelance
Jan 2025 –
Jun 2025
5 mos
Pune, MH, India
Worked as an Mechanical Design Engineer & Systems Integrator specializing in Product Design & Development for Multiple Engineering sectors providing 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 ensured every stage of development is creative, technically sound, and manufacturable. From reverse engineering an existing product, validating a new concept, or streamlining design for manufacturing, I made sure, the solutions are practical, efficient, and aligned with industry standards.
- 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
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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: June 24, 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