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Engineer Design

Burlington, North Carolina, United States
September 19, 2018

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Rohit Kulkarni

*** ******* **** *** **,

Burlington, NC, 27215



Creo 3.0, SW 2015, Agile PLM, Agile engineering connect, AutoCAD, SW EPDM, Oracle, Finite element analysis using SW simulation and Creo simulate, tolerance stackup analysis, DFM, DFMEA, sheet metal part and assembly design, solid and surface modelling,


Masterlock, Milwaukee - Product design engineer

Dec 2015 - PRESENT

Masterlock is a leading manufacturer of security products. 1. Working in the core products engineering team to solve current issues with various locks and also working on engineering of new products. 2. Using Creo 3.0, Agile EC, Agile PLM and Solidworks 2015 for CAD purposes.

3. Making 3D models of design concepts, 3D prototyping the models in connex machine and testing the prototypes

4. Using Agile EC to collaborate new product release and design maintenance process with the rest of the departments in the company. 5. Conceptual design for electronic locker lock to be used in gyms, schools, colleges, etc –

Created three concepts for the locker locks using different linkage mechanisms.

6. Conducted design reviews for the locker lock concepts. 7. Worked in a team of three engineers which solved critical problem with production padlock with a quick concept. The padlock was failing easily in the field after few knocks with a hammer. This project was financially critical for the business and required a fast solution.

8. Patent applied for the padlock mechanism design with 2 other engineers 9. Designed zinc die casting housing for electronic locker lock and zinc actuator for a padlock.

10. Made rapid prototypes of the locker lock for testing purpose. The RP model worked according to the requirements.

11. Successfully replacing lever locking mechanism with new ball bearing locking design.

12. Conducted drop test, rapping test and shackle pull test on designed padlocks.

13. Was involved in Agile EC 3.5 testing, finding bugs and inconsistencies between Agile PLM and Agile EC

R A Jones, Davenport - M echanical design engineer Feb 2014 - Nov 2015

RA Jones is engaged in designing and manufacture of automated food packaging equipment.

Worked in Innovation team – Research and development of new filling and sealing machine.

Conducted market and product research.

Conducted a research project on most commonly used cup sizes and shapes for products like yogurt, cheese, butter, etc. Involved data analysis and graphical representation of data.

Competitor research and study of different machines in the market.

Creating hand sketches and quick 3D models of design ideas for idea generation.

Making 3D models of frame and guarding for the new filling machine using Solidworks 2014.

Worked on cost reduction project of a seal less filler.

Designed lid alignment mechanism for coffee filling machine – The lid alignment with the cup was accurate to 0.010 inch after the mechanism was used. Resulted in negligible amount of cup sealing rejections. Mechanism involved design of cam and follower system, pneumatic systems, mechanical couplings, precision machined components, proximity sensors, etc.

Project management, teamwork distribution, conceptual design, 3D modelling, purchased part selection, manufacturing drawing for new food extruder.

Lead team of three engineers on coffee filling machine (Nestle) ECO’s and design errors corrections.

Worked in the modified atmosphere packaging department – Design and development of MAP systems for different packaging machines. Received training on designing MAP systems.

Designed, modelled and drafted complicated wedge shaped gassing systems for a coffee filling machine.

Designed sheet metal parts, precision machined components, sanitary weldments and plastic moulded components.

Worked extensively with manufacturing engineers and suppliers to make sure that the design was good with regards to manufacturing cost and ease of manufacturing,

Appropriate and optimal use of GD&T in drawings created. Handled every project with attention to minor details and within the given time frame.

FEA analysis on modified atmosphere packaging system components and assembly.

Technosoft engineering, Mumbai, India - D esign engineer Jan 2013 - Feb 2014

Technosoft is a highly reputable engineering services company.

Working on US client projects

Making 3D models from reference 3D scanned models

Communicating with client engineers on projects, communicating bottlenecks and project plans

Conversion of drawings from AutoCAD to Solidworks

Worked with US client that manufactures Automotive service bodies - Worked heavily on engineering changes on sheet metal parts and drawings. Trojan UV, London, Canada - Design engineer

Sep 2011 - Oct 2012

Trojan UV is market leader in designing and manufacture of UV water purification systems.

Carrying out engineering design changes using Solidworks 2010 and 2012.

Experience of using the Solidworks EPDM.

Experience of using Solidworks simulation.

Conducted FEA on highly loaded/pressurised parts such as safety caps.

Conducted CFD analysis on a reactor with water flow using Solidworks flow simulation.

Coordinating with manufacturing, planning, purchasing departments to carry out design changes.

Designed crucial components for wastewater UV system - Wiper cage seals, Lamp mounting legs this included making 3D models and manufacturing drawing using appropriate GD&T. Conducting DFMEA on design concepts.

Design of plastic parts - Injection molded and machined.

Designed a flow meter. The casing and impeller were injection moulded. Involved creating design concepts, 3D modelling, DFMEA, prototyping, testing, drawing release and production release.

Conducted several tests with pressurised reactors - Included writing HAZOP document, conducted the HAZOP, testing and writing test reports.

Successfully designed a UV sensor assembly from concepts to production release. Involved several parts. Made manufacturing and assembly drawings with detailed BOM.

Design of stainless steel enclosures using Solidworks sheet metal module.

Using Engineering change process for making design modification for existing products.

Making prototypes of designs and testing the prototypes.

Worked on sealing of enclosures for UL and CSA certification.

FEA of sleeve bolts mounted on highly pressurised vessels and optimisation of the design according to the FEA results.

Pavegen systems, London, UK - M echanical engineer Oct 2010 - Aug 2011

Pavegen is a unique startup engaged in making energy harvesting pavement slabs.

Design and detailing for mechanical parts of energy generating paving slab using Solidworks 2010.

Conducting FEA analysis on the load bearing sections of Pavegen using Solidworks 2010.

Making 3D models of concepts arising from brainstorming sessions.

Cost saving initiatives - Reduced the price of the product by 10%.

Communicating with the suppliers about the design intent and requirements.

Conducting quality checks after receiving parts from the supplier and checking conformance with the design.


Brunel University, London, UK - Master’s Advanced engineering design

Sep 2009 - Sep 2010

Key modules:

Advanced computer aided Engineering

Design experience- Design and development of an automatic railway barrier-

Physical human factors in design

Structural design and FEA

Design of Mechatronics systems

Dissertation: Structural analysis of Jones & Shipman cylindrical grinding machine using Finite Element Analysis. Dissertation focused on optimising the machine structure design. Static, modal and dynamic analysis was conducted on the grinding machine model FEA. The harmonic response of the machine was obtained by conducting a hammer impact test on the actual machine. The structure was simulated in FEA software to find the values of natural frequencies of main structural components and assembly. The stiffness of structure was calculated using the values obtained by FEA simulations. The bed structure was altered and different materials were applied to the structure to achieve the lowest cost while keeping the stiffness same. Used Solidedge for the purpose of simplifying 3D models of the grinding machine. Used Abaqus for conducting finite element analysis on the assembly. Pune University, Pune, India - Bachelor’s in Production engineering Jul 2004 - July 2007

Sinhgad institute, Pune, India - D iploma in Mechanical engineering Jul 2004 - July 2007


Patent applied for padlock mechanism design at Masterlock

Successfully completed research project while working at Trojan UV on effect of continuous exposure of UV C light and water flow on various types of plastic test samples.

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