Sam J.
Senior Mechanical & DFM Engineer | M.Tech | SolidWorks & SolidCAM | CFD & Prusa 3D Printing | ANSYS
Korba,
India
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About
Senior Mechanical & Design for Manufacturing (DFM) Engineer with an M.Tech in Mechanical Engineering (8.22 CGPA) and industry experience at Cummins India.
Specialized in precision mechanism design, kinematics, structural & thermal multi-physics simulation, and advanced manufacturing workflows.
Core Engineering Competencies:
• CAD & DFM/DFA: SolidWorks, Siemens NX, complex parametric surface & solid modeling, plastic injection molding, sheet metal, and GD&T tolerance stack-up analysis (ASME Y14.5).
• Advanced FEA & CFD: Nonlinear contact stress analysis, dynamic load cases (cornering/braking/shock), modal & fatigue evaluation, and aerodynamic flow trajectories (ANSYS Workbench & SolidWorks Simulation).
• Manufacturing & CAM: SolidCAM (multi-axis CNC milling & turning), additive manufacturing specialization in Wire Arc Additive Manufacturing (WAAM), and slicing optimization with PrusaSlicer.
• Kinematics & Mechatronics: Multi-body vehicle dynamics, automated robotic palletizing cells, and electromagnetic solenoid/actuator FEA.
Featured Track Record & Projects:
• Formula EV Racing: Full double-wishbone suspension, custom uprights, steering knuckles, and aerodynamic CFD with nonlinear contact FEA.
• Industrial Automation: Turnkey palletizing robotic workcell design with custom pneumatic/mechanical gripper tooling and layout.
• Plastics DFM: Comprehensive injection molding mold-flow simulation (fill time, volumetric shrinkage, clamp tonnage, and sink mark optimization).
• Cummins India: BSFC shift pattern optimization for automated manual transmissions (AMT) and duty cycle telemetry analytics.
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Specialized in precision mechanism design, kinematics, structural & thermal multi-physics simulation, and advanced manufacturing workflows.
Core Engineering Competencies:
• CAD & DFM/DFA: SolidWorks, Siemens NX, complex parametric surface & solid modeling, plastic injection molding, sheet metal, and GD&T tolerance stack-up analysis (ASME Y14.5).
• Advanced FEA & CFD: Nonlinear contact stress analysis, dynamic load cases (cornering/braking/shock), modal & fatigue evaluation, and aerodynamic flow trajectories (ANSYS Workbench & SolidWorks Simulation).
• Manufacturing & CAM: SolidCAM (multi-axis CNC milling & turning), additive manufacturing specialization in Wire Arc Additive Manufacturing (WAAM), and slicing optimization with PrusaSlicer.
• Kinematics & Mechatronics: Multi-body vehicle dynamics, automated robotic palletizing cells, and electromagnetic solenoid/actuator FEA.
Featured Track Record & Projects:
• Formula EV Racing: Full double-wishbone suspension, custom uprights, steering knuckles, and aerodynamic CFD with nonlinear contact FEA.
• Industrial Automation: Turnkey palletizing robotic workcell design with custom pneumatic/mechanical gripper tooling and layout.
• Plastics DFM: Comprehensive injection molding mold-flow simulation (fill time, volumetric shrinkage, clamp tonnage, and sink mark optimization).
• Cummins India: BSFC shift pattern optimization for automated manual transmissions (AMT) and duty cycle telemetry analytics.
Design Entries
Experience
-
Mechanical Engineer
Cummins India Pvt Ltd · Full-time
Jun 2026 –
Present
4 mos
Pune, MH, India
Mechanical Engineer | CTCI Fleet: Directed shop floor management and executed physical vehicle integration, ensuring digital CAD models translated perfectly to real-world manufacturing environments.
Mechanical Engineering Intern | Cummins India (June 2025 – Dec 2025): Contributed to industrial powertrain engineering, optimization, and mechanical design workflows.
Education
- DEFENCE INSTITUTE OF ADVANCE TECHNOLOGY MTECH, Mechanical engineering, 8.22 2024 – 2026 Mechanical Engineering: Comprehensive foundation in applied mechanics, machine design, and thermodynamics. Formally qualified with a valid GATE score for advanced graduate-level engineering.
Other experience
- Programming Algorithmic Computing: Developed highly optimized, multithreaded scripts and technical computing environments using Python and C++ to interface with APIs and local CUDA-accelerated hardware.
- Simulation and Manufacturing Advanced Systems Simulation: Extensive applied research in terramechanics and vehicle dynamics. Built multi-body physics simulations utilizing Project Chrono and the Bekker-Wong model to map HMMWV engine performance and extract dynamic force data.
Licenses & Certifications
- M.Tech - Defence Institute of Advanced Technology (DIAT), Pune Jan 2022 – Present
- Production Design Engineering - Cummins India Ltd. Jan 2020 – Present
Stats
2 followers, 0 following
Joined: July 9, 2026
Last seen: October 6, 2026
Area of Expertise
Languages
Hindi Native or bilingual proficiency
English Native or bilingual proficiency
Location
Korba, India