Ashley D.
Mechanical CAD Engineer | Design for Additive Manufacturing | Production-Ready Models
Bengaluru,
India
Global rank:
11,767
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121,672
Skill pts: 5
About
I’m a mechanical design engineer specializing in Design for Additive Manufacturing (DfAM), with 6+ years of experience developing production-intent and prototype-ready components in the automotive domain. I currently work as Deputy Manager – Technology Demonstration & Innovation at TVS Motor Company R&D Division, where rapid iteration, tight packaging, and cost-driven engineering are everyday constraints.
My work involves designing parts specifically for 3D printing (FDM, SLA, SLS)—optimizing geometries for strength, weight, print orientation, support minimization, and post-processing—while ensuring designs remain transferable to CNC or injection molding when needed. I regularly use additive manufacturing to validate mechanisms, airflow paths, ergonomics, and assembly logic before committing to tooling.
I bring a production engineer’s mindset to additive design: clean parametric CAD, realistic tolerances, serviceability considerations, and clear documentation so parts don’t fail at the printer—or later in the field.
If you need DfAM that goes beyond “printable” and into functional, testable, and scalable, I’m a strong fit.
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My work involves designing parts specifically for 3D printing (FDM, SLA, SLS)—optimizing geometries for strength, weight, print orientation, support minimization, and post-processing—while ensuring designs remain transferable to CNC or injection molding when needed. I regularly use additive manufacturing to validate mechanisms, airflow paths, ergonomics, and assembly logic before committing to tooling.
I bring a production engineer’s mindset to additive design: clean parametric CAD, realistic tolerances, serviceability considerations, and clear documentation so parts don’t fail at the printer—or later in the field.
If you need DfAM that goes beyond “printable” and into functional, testable, and scalable, I’m a strong fit.
Experience
-
Part Design Engineer - Deputy Manager
TVS Motor Company · Full-time
Aug 2019 –
Present
6 yrs 6 mos
Bengaluru, KA, India
->Led DfAM-driven mechanical design for automotive sub-systems at TVS Motor Company, using additive manufacturing as a primary tool for rapid validation and iteration, reducing concept-to-prototype cycles by 60–70%.
->Designed and optimized 50+ functional 3D-printed components (FDM, SLA, SLS) including housings, ducts, brackets, valve bodies, and ergonomic parts—validated for fit, airflow, load paths, and assembly.
->Applied DfAM principles (print orientation, wall thickness optimization, lattice infill, overhang control, and support minimization) to reduce print time by up to 40% and material usage by ~30% per iteration.
->Enabled early-stage design freeze by replacing machined prototypes with additively manufactured functional parts, saving ₹15–20 lakh per project in tooling and prototype costs.
->Integrated additive manufacturing into system-level design validation, supporting mechanism motion checks, pneumatic routing, tolerance stack-ups, and ergonomic studies before production tooling.
->Transitioned additive-first designs to production-friendly geometries (CNC / injection molding) with minimal rework, ensuring scalability beyond prototyping.
->Primary inventor on multiple patented mechanical systems where additive manufacturing was used to de-risk architecture and packaging in early development phases.
Education
- HAN University of applied sciences Master of Science, Automotive Systems 2016 – 2018
- Manipal Institute of Technology Bachelor of Technology, Mechanical Engineering 2012 – 2016
Stats
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Joined: February 2, 2026
Last seen: February 3, 2026
Area of Expertise
Languages
English Native or bilingual proficiency
Hindi Limited working proficiency
Location
Bengaluru, India