Rathna K.

Experience

• Lead Engineer HCL TECHNOLOGIES · Full-time Apr 2022 – Present 4 yrs 7 mos Bengaluru, Karnataka, India I design mechanical and electro-mechanical components for semiconductor capital equipment, working on ETCH platform modules where precision is measured in microns. From cathode plate and HVM enclosure assemblies to ESC connector and heater cable packaging, I take designs from 3D CAD to release-ready MBD drawings and BOMs using Siemens NX and Teamcenter PLM. I apply tolerance stack-up analysis and SEMI standards to keep high-precision tools reliable, and my VAVE work on gas line fittings saved $15,000. I also built a reliability qualification test framework for a new shutter sensor box, validating its detection performance and structural integrity for wafer fab monitoring.
• Mechanical Design Engineer LMW Limited · Full-time Jun 2022 – Apr 2026 3 yrs 10 mos Coimbatore, Tamil Nadu, India 1. Led end-to-end product development, from concept to productization, for sheet metal and machined components on Drawframe and Comber textile machinery.
  2. Designed medium-complex mechanical sub-systems, including carrier roller assemblies with integrated spring and pneumatic mechanisms, drive systems, cam and follower door actuation, and kinematic linkages.
  3. Did design calculations for shafts, bearings, springs (torsion, helical, gas), output torque, and pneumatic cylinder selection.
  4. Ran FEA (static and stress analysis) in Siemens NX to validate critical assemblies and structural loads.
  5. Applied GD&T (ASME Y14.5) and tolerance stack-up analysis to ensure precise fitment and dimensional compliance.
  6. Carried out DFMEA and design validation to improve reliability. Eliminated recurring machine failures by specifying electroless nickel coating.
  7. Selected materials (aluminium, CRS, HRS, plastics) and components such as gas springs, belts, fasteners, and tension elements.
  8. Researched competitor products and patents, and re-engineered them into improved designs.
  9. Created 2D drawings and MBD for systems, sub-systems, and components, and released them through Teamcenter PLM via the ECR/ECO process.
  10. Managed BOMs and technical documentation, and worked directly with shop-floor teams to confirm manufacturing feasibility.
  
  Cost Savings Achieved
  
  1. ₹25,000 saved through sheet metal redesign and BOM teardown.
  2. 76% cost reduction by replacing gas springs with a torsion spring mechanism.
  3. 13.3% saving by eliminating a counterbore process.
  
  Key Projects
  
  1. Auto Lap Piecing Carrier Roller Assembly: Designed a complex assembly combining a spring mechanism and pneumatic actuation, taking it from concept to production release.
  2. Torsion Spring Redesign (Comber LK69S/M): Replaced a failed gas spring mechanism with a custom helical torsion spring. Calculated wire diameter, active coil count, and spring index to meet the required angular deflection and load. Delivered a 76% cost reduction and better machine uptime.
  3. Diverting Roller Mechanism: Improved sliver quality (U% efficiency) through an innovative spring mechanism design.
  4. Easy-Cleaning Door System: Designed an accessible door system that cuts downtime and improves maintenance productivity on the production floor.