Saksham K.

Experience

• Junior Engineer Axlr8r Formula Racing · Part-time Jan 2026 – Jan 2026 0 mos New Delhi, DL, India Development of an open-wheel Formula Style Racecar with Hybrid Chassis, 400V Battery, Dual 52kW Motors with E- Differential Liquid-cooled Powertrain and 3-Element Airfoils for International FSAE Competitions
  
  - Redesigned multi-stage gearbox into a single-stage planetary unit, reducing complexity and weight (by 25%)
  
  - Performed hand calculations and FEA simulations to verify structural integrity and safety factors of various components
  
  - Drafted roadmap for future in-wheel gearboxes (4WD), with a focus on on mass decentralization and compact packaging
  
  - Oversaw part manufacturing via CNC, waterjet, Lathe and EDM , ensuring tolerances (±0.1mm) matched design specifications
  
  - Conducted shakedown analysis, FMEA, and DVP to verify performance and identify potential failure modes pre-comp
  
  - Executed dynamic testing and data analysis to fine-tune subsystem performance for optimal race reliability
  
  - Developed a transient thermo-structural simulation of a brake disc under thermal loading to observe thermal stresses
  
  - Simulated cooling via convection and radiation using DO models, ideal gas flow, and MRF-based disc rotation in ANSYS Fluent
  
  - Quantified thermal performance: Slot-only cooling outperformed holes-only by ~10%, reaching a lower final temperature of 390K vs 431K
  
  - Solved convergence and mesh errors through custom boundary conditions, dynamic frame setups, and mesh tuning