About
Hi, I’m Pavan Tejaswi Velivela. I am a New Product Development (NPD) researcher with over 4 years of experience in developing and applying systematic, bio-inspired methods to design and engineer new, multifunctional products. My work lies in interdisciplinary design and engineering, with a focus on bio-inspired innovation and early-stage product ideation.
My work sits at the intersection of product design, mechanical engineering, bioinspiration (with a focus on morphology), and emerging AI technologies (integration currently in progress).
I hold a PhD in mechanical engineering, where I developed a novel front-end, systematic ideation method for the conceptual design and engineering of bio-inspired multifunctional structures, products, and devices. This method, known as the MBID ideation system, bridges biological insight with engineering creativity to support innovation across disciplines.
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Research
The MBID ideation system is a structured, morphology-driven design framework that combines a systematic methodology with an interactive data visualisation tool, enabling the generation of next-generation multifunctional structures and products. The MBID ideation system provides a structured process bridging early-stage problem definition and embodiment design with functional verification.
The MBID ideation system is a structured, morphology-driven design framework that combines a systematic methodology with an interactive data visualisation tool, enabling the generation of next-generation multifunctional structures and products. The MBID ideation system provides a structured process bridging early-stage problem definition and embodiment design with functional verification.
Focusing on morphological (passive structural) solutions, MBID minimises reliance on active components (like sensors, actuators, or external power), thereby reducing energy demands and system complexity. It supports the creation of sustainable, efficient, and multifunctional designs by harnessing material and geometric intelligence inspired by biology.
Access the MBID ideation system here—
Access the MBID ideation system here—
This research is funded by the Natural Sciences and Engineering Research Council of Canada (NSERC) & McGill University and supervised by Prof. Yaoyao Fiona Zhao (Director of Additive Design & Manufacturing Laboratory, McGill University)
MBID ideation system
Embodiment designs & Validation
Embodiment designs & Validation
Helmets for protection against head injury
By combining reduced drag, impact absorption, and sweat absorption, the bio-inspired helmets offer enhanced protection and usability against head injuries.
Comparative biological feature analysis:The phenomenon of convergent evolution, where distantly related organisms independently develop similar functions, adds to this complexity. This study introduces novel meta-level design parameters that systematically guide the selection of biological features with differing geometries yet analogous functions. These parameters were derived through physical testing and numerical analysis of woodpecker-beak-inspired and Balanus-inspired structures, focusing specifically on their impact resistance capabilities. The results highlight the potential for practical application in products such as bicycle helmet liners.
Team:Pavan Tejaswi Velivela, Nikita Letov, & Yaoyao Fiona Zhao
Acknowledgement:We gratefully acknowledge Dr. Chris Whitehall of Biokinetics and Associates Ltd., Ottawa, Canada, for his support in setting up the experimental apparatus and providing valuable guidance throughout the testing process.
Comparative biological feature analysis:The phenomenon of convergent evolution, where distantly related organisms independently develop similar functions, adds to this complexity. This study introduces novel meta-level design parameters that systematically guide the selection of biological features with differing geometries yet analogous functions. These parameters were derived through physical testing and numerical analysis of woodpecker-beak-inspired and Balanus-inspired structures, focusing specifically on their impact resistance capabilities. The results highlight the potential for practical application in products such as bicycle helmet liners.
Team:Pavan Tejaswi Velivela, Nikita Letov, & Yaoyao Fiona Zhao
Acknowledgement:We gratefully acknowledge Dr. Chris Whitehall of Biokinetics and Associates Ltd., Ottawa, Canada, for his support in setting up the experimental apparatus and providing valuable guidance throughout the testing process.
Marine skins
This skin technology combines weight reduction and drag minimisation, making it ideal for marine applications, such as deep-sea exploration.
Comparative biological feature analysis: Different biological features independently evolve characteristics to solve the same need/necessity. This phenomenon is called convergent evolution. Without parameters, selecting a suitable feature from those that exhibit the same function and have the same geometric relevance becomes quite difficult.
This research identifies and investigates key parameters that support the selection of suitable biological features and enable the generation of multifunctional design concepts. These parameters are hypothesised by examining the mechanisms of tissue formation that lead to the emergence of structural features in biological systems. The resulting insights are integrated into the Expandable Domain Integrated Design (xDID) ideation model, which aids designers in selecting and combining biological features to develop multifunctional concepts.
Team:Pavan Tejaswi Velivela, Arnaud Ridard, & Yaoyao Fiona Zhao
Comparative biological feature analysis: Different biological features independently evolve characteristics to solve the same need/necessity. This phenomenon is called convergent evolution. Without parameters, selecting a suitable feature from those that exhibit the same function and have the same geometric relevance becomes quite difficult.
This research identifies and investigates key parameters that support the selection of suitable biological features and enable the generation of multifunctional design concepts. These parameters are hypothesised by examining the mechanisms of tissue formation that lead to the emergence of structural features in biological systems. The resulting insights are integrated into the Expandable Domain Integrated Design (xDID) ideation model, which aids designers in selecting and combining biological features to develop multifunctional concepts.
Team:Pavan Tejaswi Velivela, Arnaud Ridard, & Yaoyao Fiona Zhao
Heat absorption & low-pressure drop structures
This new conceptual design integrates effective heat transfer with low-pressure drop characteristics, offering potential applications in gas turbine engines for aerospace systems. Inspired by the labyrinthine structures of camel nostrils—known for minimising pressure loss and heat absorption—and the micro-bumps found on the surface of the Namib Desert beetle—used to enhance surface area and promote heat transfer—the design strategically combines these biological features.The visual representation showcases concentric tubes mimicking the intricate turbinates of camel nostrils, while semi-spherical projections on the tube surfaces replicate the beetle’s micro-bumps.The performance of the bio-inspired structure was evaluated against a range of lattice structures. Results indicate that the bio-inspired design exhibits superior performance in terms of pressure drop and remains comparable to primitive lattice structures in overall thermal–fluidic effectiveness.Team:Shivangi Sarabhai, Pavan Tejaswi Velivela, Yaoyao Fiona Zhao, Fabian Sanchez, & Mitch Kibsey
Industry collaboration:Siemens Energy Ltd, Canada
Industry collaboration:Siemens Energy Ltd, Canada
Non-pneumatic tyres
This concept in non-pneumatic tyre design demonstrates multifunctionality through effective friction management and impact resistance, with potential applications in extraterrestrial rovers and high-terrain vehicles. The design draws inspiration from the anisotropic microscopic texture of snakeskin for directional friction control and from the diverse porous cellular structures found in the pomelo peel and the woodpecker’s beak for enhanced energy absorption and structural resilience.Comparative Biological Feature Analysis:
To select the most effective structure from among cellular configurations offering similar functions (such as those of the pomelo peel and the woodpecker’s beak), a meta-level design parameter was introduced. This parameter was validated through a simulation-based study, demonstrating its utility in guiding multifunctional design selection.Team:Pavan Tejaswi Velivela, Nikita Letov, Lingchen Kong, Yaoyao Fiona Zhao
To select the most effective structure from among cellular configurations offering similar functions (such as those of the pomelo peel and the woodpecker’s beak), a meta-level design parameter was introduced. This parameter was validated through a simulation-based study, demonstrating its utility in guiding multifunctional design selection.Team:Pavan Tejaswi Velivela, Nikita Letov, Lingchen Kong, Yaoyao Fiona Zhao
Painless sutures
Drawing inspiration from the kingfisher’s beak and porcupine quills, the conceptual design of the suture pin employs a unique ideation methodology developed in this research, known as Domain Integrated Design (DID). This methodology classifies bio-inspired structures across various domains, with a particular emphasis on multifunctionality. Biological functionalities are organised into domains such as cellular structures, shapes, cross-sections, and surfaces. Multifunctional bio-inspired structures are then generated by integrating features across these domains.The design hypothesis is rigorously tested by simulating the total deformation of both tissue and needle during puncture. The results indicate that the bio-inspired suture pin causes lower tissue deformation at higher puncture velocities and exhibits minimal structural deformation when an axial (reaction) force is applied at its tip. This enhanced stiffness reduces the force required for insertion, potentially improving surgical efficiency and reducing patient discomfort.Team:Pavan Tejaswi Velivela, Nikita Letov, Yuan Liu, Yaoyao Fiona Zhao
Other conceptual design & engineering
Masking materials & bio-inspired caps for chemical etching of dental implants
Osseointegration is a critical factor in the successful anchorage of implants to bone. This process is typically enhanced by micro-roughening the implant surface using techniques such as sandblasting followed by chemical etching, which facilitates a strong mechanical interlock with the surrounding bone to improve implant stability. However, surface protection is primarily necessary for the region intended to function as the artificial tooth root. Currently, there is limited literature addressing the behaviour of dental implants undergoing chemical treatment processes.
This study investigates the use of low-surface energy (LSE) polymer tapes and chemically inert materials, alongside bio-inspired cap designs, to protect the upper portion of dental implants during chemical etching. LSE tapes, known for their chemical resistance, are capable of withstanding the aggressive nature of acid treatments. Meanwhile, bio-inspired caps are designed to function as sealing agents, offering superior grip and flexibility to shield the implant surface effectively.
The study also explores a novel application of claw-inspired structures, traditionally associated with attachment or penetration, reimagined here as flexible and secure sealing elements for implant surface protection during etching.
Mentors:Dr Monica Moscatelli (Department of Chemistry, Materials and Chemical Engineering "Giulio Natta", Politecnico di Milano)
Prof Roberto Chiesa (Department of Chemistry, Materials and Chemical Engineering "Giulio Natta", Politecnico di Milano)
This study investigates the use of low-surface energy (LSE) polymer tapes and chemically inert materials, alongside bio-inspired cap designs, to protect the upper portion of dental implants during chemical etching. LSE tapes, known for their chemical resistance, are capable of withstanding the aggressive nature of acid treatments. Meanwhile, bio-inspired caps are designed to function as sealing agents, offering superior grip and flexibility to shield the implant surface effectively.
The study also explores a novel application of claw-inspired structures, traditionally associated with attachment or penetration, reimagined here as flexible and secure sealing elements for implant surface protection during etching.
Mentors:Dr Monica Moscatelli (Department of Chemistry, Materials and Chemical Engineering "Giulio Natta", Politecnico di Milano)
Prof Roberto Chiesa (Department of Chemistry, Materials and Chemical Engineering "Giulio Natta", Politecnico di Milano)
Introduction to Flux: A thermotherapy device for patients with rheumatism
Device description:Flux is an automated thermotherapy device designed to support patients with rheumatism. Its functionality complies with established medical regulations and aligns with standards observed in comparable products on the market.
Device characteristics:The device delivers hot, cold, and contrast thermotherapy, as well as light pressotherapy, all in an automated and integrated manner. Its settings can be personalised according to a doctor’s prescription. Patients are able to adjust treatment duration and temperature within safe limits predefined by their healthcare provider.
Device operation:The base of the device houses two water containers, which users fill as needed. While the water requires periodic replacement, it does not need to be changed after every use. Hot water is generated via a built-in heating element, whereas cooling is achieved either automatically—through the thermoelectric effect—or manually, by adding ice to the designated container. A gear pump circulates water to a cuff worn by the patient, with directional valves controlling the flow of hot or cold water based on the selected therapy mode.
Team:Martina Scagnoli, Michele Colucci, Pavan Tejaswi Velivela, & Zhana Petrova
Industry collaboration:Dolphin Fluidics, Italy & Fluid-O-Tech, Italy
Device characteristics:The device delivers hot, cold, and contrast thermotherapy, as well as light pressotherapy, all in an automated and integrated manner. Its settings can be personalised according to a doctor’s prescription. Patients are able to adjust treatment duration and temperature within safe limits predefined by their healthcare provider.
Device operation:The base of the device houses two water containers, which users fill as needed. While the water requires periodic replacement, it does not need to be changed after every use. Hot water is generated via a built-in heating element, whereas cooling is achieved either automatically—through the thermoelectric effect—or manually, by adding ice to the designated container. A gear pump circulates water to a cuff worn by the patient, with directional valves controlling the flow of hot or cold water based on the selected therapy mode.
Team:Martina Scagnoli, Michele Colucci, Pavan Tejaswi Velivela, & Zhana Petrova
Industry collaboration:Dolphin Fluidics, Italy & Fluid-O-Tech, Italy
Introduction to Sibilla: A Portable Coffee Innovation
Embracing the evolving trends in coffee consumption, Sibilla is an innovative portable coffee machine designed to meet the dynamic lifestyle needs of modern users. Inspired by De'Longhi's drip coffee mechanism, Sibilla specifically targets individuals aged 15–40, with a primary focus on working professionals seeking the convenience of high-quality coffee during work hours or while travelling.
Market Insight: Catering to User PreferencesInsights from a user survey revealed that a significant segment—particularly students and professionals—prefer consuming coffee at their workplace or educational institution. Respondents highlighted the importance of both the coffee experience and beverage quality. These insights directly informed the conceptual development of Sibilla, ensuring it addresses both functional needs and user expectations.
Team:Sergio Vezzani, Pavan Tejaswi Velivela, & Sun Ziwen
Industry collaboration:De'Longhi S.p.A., Italy
Market Insight: Catering to User PreferencesInsights from a user survey revealed that a significant segment—particularly students and professionals—prefer consuming coffee at their workplace or educational institution. Respondents highlighted the importance of both the coffee experience and beverage quality. These insights directly informed the conceptual development of Sibilla, ensuring it addresses both functional needs and user expectations.
Team:Sergio Vezzani, Pavan Tejaswi Velivela, & Sun Ziwen
Industry collaboration:De'Longhi S.p.A., Italy
Educational Plant Watering Tool for Pre-schoolers: A Child-Centric Design
Designed to introduce preschool children to the world of plants, Daisy is an educational tool that teaches essential watering techniques through a playful and ergonomic approach. Inspired by conventional spray gun nozzles, Daisy has been reimagined to suit the small hands of young children—prioritising comfort, safety, and ease of use.
Key features:Daisy features a variety of spray nozzles, each designed for a distinct watering method. To support learning through play, the nozzles are colour-coded, helping children identify and distinguish between different spray patterns. Complementing this, a set of matching plastic labels allows parents to assign specific spray types to individual plant pots—transforming gardening into an interactive, hands-on experience that fosters curiosity, independence, and environmental awareness.
Team:Sergio Vezzani, Pavan Tejaswi Velivela, Sun Ziwen, & Sofya Komarova
Key features:Daisy features a variety of spray nozzles, each designed for a distinct watering method. To support learning through play, the nozzles are colour-coded, helping children identify and distinguish between different spray patterns. Complementing this, a set of matching plastic labels allows parents to assign specific spray types to individual plant pots—transforming gardening into an interactive, hands-on experience that fosters curiosity, independence, and environmental awareness.
Team:Sergio Vezzani, Pavan Tejaswi Velivela, Sun Ziwen, & Sofya Komarova
Biomedical Engineering Design Project: Instrument-Tissue Interaction in Spinal Surgery
Conducted as part of the Biomedical Engineering Design course (WB2308) at TU Delft, this project focuses on developing an innovative medical device for separating muscle bundles during spinal surgery. Categorised under Instrument–Tissue Interaction 1, the design aims to minimise collateral damage to surrounding tissues during surgical procedures.
Design objective:The primary goal is to create a surgical instrument that enables precise separation of tissue layers, particularly in complex anatomical regions such as the spine. The device is intended to enhance the accessibility of conventional minimally invasive instruments by forming a straight tunnel between tissue layers. The straightness of this tunnel is critical, as it allows instruments to reach areas located behind the separated tissues while maintaining minimal invasiveness and preserving healthy tissue.
Scope:The project specifically addresses challenges in spinal surgery, with skeletal muscle identified as the target tissue for separation. By focusing on this application, the project contributes to the ongoing advancement of minimally invasive surgical techniques, aiming to improve surgical outcomes and patient recovery.
Team:Teunis van Manen, Pavan Tejaswi Velivela, & Anna Krisztina Szkely
Design objective:The primary goal is to create a surgical instrument that enables precise separation of tissue layers, particularly in complex anatomical regions such as the spine. The device is intended to enhance the accessibility of conventional minimally invasive instruments by forming a straight tunnel between tissue layers. The straightness of this tunnel is critical, as it allows instruments to reach areas located behind the separated tissues while maintaining minimal invasiveness and preserving healthy tissue.
Scope:The project specifically addresses challenges in spinal surgery, with skeletal muscle identified as the target tissue for separation. By focusing on this application, the project contributes to the ongoing advancement of minimally invasive surgical techniques, aiming to improve surgical outcomes and patient recovery.
Team:Teunis van Manen, Pavan Tejaswi Velivela, & Anna Krisztina Szkely
Innovative Electric Motor Project at IIT Bombay's Industrial Design Center
This project, undertaken during the summer internship programme at the Industrial Design Centre (IDC) of IIT Bombay, focuses on converting a Brushless DC Motor (BLDC) into a Switched Reluctance Motor (SRM). The objective is to improve torque performance—particularly for hub motors used in electric vehicles.
Project details:The key challenge was to convert a BLDC motor into an SRM while increasing the gear ratio and maintaining a power output comparable to the original design. The project involved multiple stages, including conceptual sketching, detailed design using CATIA V5, and the development of a demonstrative prototype.
Specifications:To meet performance goals, the motor’s gear ratio was strategically increased without compromising power output. The prototype integrated materials such as styrene, PU foam, and PVC, offering a tangible representation of the re-engineered motor. This project exemplifies the integration of design thinking, digital tools, and physical prototyping—demonstrating a viable approach to advancing electric motor technology for electric mobility applications.
Mentors:Prof. Kishor Munshi (IDC, IIT Bombay)Mr. Govinda Rajan (Project Engineer, IDC, IIT Bombay)Prof. Shyam Prasad Kodali (Department of Mechanical Engineering, K.L. University)
Project details:The key challenge was to convert a BLDC motor into an SRM while increasing the gear ratio and maintaining a power output comparable to the original design. The project involved multiple stages, including conceptual sketching, detailed design using CATIA V5, and the development of a demonstrative prototype.
Specifications:To meet performance goals, the motor’s gear ratio was strategically increased without compromising power output. The prototype integrated materials such as styrene, PU foam, and PVC, offering a tangible representation of the re-engineered motor. This project exemplifies the integration of design thinking, digital tools, and physical prototyping—demonstrating a viable approach to advancing electric motor technology for electric mobility applications.
Mentors:Prof. Kishor Munshi (IDC, IIT Bombay)Mr. Govinda Rajan (Project Engineer, IDC, IIT Bombay)Prof. Shyam Prasad Kodali (Department of Mechanical Engineering, K.L. University)
Innovative Low-Cost Prosthetic Foot Design
This project centres on the development of an affordable and simplified prosthetic foot joint, specifically designed to support individuals with below-knee amputations. Inspired by stress analysis and the pressure distribution of the human foot, the design aims to balance functionality with accessibility.
Key features:The prosthetic foot joint is thoughtfully designed to allow for easy component replacement, making it a cost-effective solution for users. A ball-joint connection at the ankle enhances flexibility and enables a natural range of motion, significantly improving user comfort and mobility.
Objective:The primary objective is to simplify existing prosthetic foot joint designs while reducing production and maintenance costs. Through detailed analysis of foot anatomy, structural stress, and pressure points, this project contributes to making prosthetic devices more accessible, particularly for underserved populations.
Mentors:Prof. Yalala Kalyana Chakravarthy (Department of Mechanical Engineering, K.L. University)Prof. A. Srinath (Department of Mechanical Engineering, K.L. University)
Key features:The prosthetic foot joint is thoughtfully designed to allow for easy component replacement, making it a cost-effective solution for users. A ball-joint connection at the ankle enhances flexibility and enables a natural range of motion, significantly improving user comfort and mobility.
Objective:The primary objective is to simplify existing prosthetic foot joint designs while reducing production and maintenance costs. Through detailed analysis of foot anatomy, structural stress, and pressure points, this project contributes to making prosthetic devices more accessible, particularly for underserved populations.
Mentors:Prof. Yalala Kalyana Chakravarthy (Department of Mechanical Engineering, K.L. University)Prof. A. Srinath (Department of Mechanical Engineering, K.L. University)
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