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As project lead, I directed a cross-functional team of mechanical, electrical, and computer science engineers to design and prototype an electric two-wheeler. The challenge was to create a lightweight, durable, and manufacturable vehicle that could be built within a tight timeline.
I developed the master CAD design in SolidWorks, applying DFM/DFA principles to ensure manufacturability. Using Ansys for FEA and structural simulations, I validated load-bearing components and optimized the frame design. Through topology optimization and structural analysis, I achieved a 12% weight reduction without compromising safety or performance — a critical trade-off in mobility solutions.
Prototyping and validation were central to our process. We built scaled and full-size prototypes, tested weld strength and deformation, and compared results against simulations. The outcome was an 80% correlation between virtual analysis and physical tests, which reinforced the accuracy of our design process.
I also took ownership of mechanical–electrical integration, collaborating with the electrical team to design the harness layout, motor, and battery placement. With limited prior exposure to electrical systems, I quickly self-taught PCB and harness fundamentals to ensure compatibility with the mechanical design. This experience pushed me out of my comfort zone and deepened my interest in electro-mechanical product design.
The project was delivered 20 days ahead of schedule, thanks to structured planning and effective team coordination. Beyond the technical results, I learned the importance of designing for manufacturability, validating early through simulation, and leading a multidisciplinary team toward a shared vision. Most importantly, this project solidified my passion for creating electro-mechanical products that move seamlessly from CAD to real-world impact.
Key Skills: SolidWorks, Ansys (FEA/structural analysis), Topology Optimization, DFM/DFA, Prototyping & Validation, Mechanical–Electrical Integration, Cross-functional Leadership
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