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Mechanical Engineer Design

Scottsdale, AZ
December 26, 2020

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480-***-**** **** S Stanley Pl., Tempe, AZ

LinkedIn: rahulverma120491


Established Mechanical Engineer Master's grad with 3+ yrs of exp. in prototyping & design, product management, rendering, fabrication, 3D printing, 3D scanning, continuous improvement, manufacturing and mechatronic systems.


Inventor, Solidworks Fusion 360, Meshmixer

Design for Manufacturability & Reliability

3D Scanning and post processing

3D Printing, Sheet Metal Design

Structural, CFD, Thermal (FEA)

Computer Aided Manufacturing (CAM Router based)

Reverse Engineering

Project Management

Failure Mode Effect Analysis (FMEA)

Tolerance Stack up Analysis (GD&T)

ISO 9001:2015 implementation

Root Cause Analysis, Risk Management


Master of Science, Mechanical Engineering 3.3 GPA (Dec 2018)

Arizona State University, Tempe, AZ

Bachelor of Engineering, Mechanical Engineering 3.4 GPA (Jan 2014)

Gujarat Technological University, India

RELEVANT COURSEWORK: Lean Systems, Modern Manufacturing methods, Polymers & composites, CAD Design & Modeling techniques, Heat & Mass Transfer, Fluid Mechanics, Six Sigma Foundations, Mechanics of Solids


Design Engineer, Project Management, Quality, Business Development Aug‘20-Present Vector Technology Systems – Gilbert, AZ

•Managing, supervising, and implementing ISO 9001: 2015 standard, 5S, and other quality systems.

•Design products on Solidworks, Fusion 360 as per client specification, verify and validate them as per the market.

•Create and manage project ecosystem on for efficient delegation to cross functional teams.

•Managing 3D printing services for big clients like Northrop Grummen, Intel, etc.

•Conceptualize new products, do market research, product cost breakdown, and preparing house of quality.

•3D Scan products to reverse engineer for prototyping and business needs. Post processing meshing using Meshmixer.

•Managing business development needs for business expansion and new revenue generation.

Mechanical Engineer Sept‘19-Present Digital Building Components – Phoenix, AZ

•Use SolidWorks, Autodesk Inventor and Fusion 360 to design, draft and develop in-house equipment.

•Use in-house 3D printer for prototyping purposes.

•Perform FEA analysis on structural members and mechanical components to design for integrity and safety.

•Create facility layouts and building models on Autodesk Revit using Architect and client specifications.

•Provided technical guidance and leading the production automated tool inventory system inhouse project.

•Prepared and presented a business Cost Analysis for the feasibility of plasma and water jet cutting machine for inhouse use.

•Supervised ASTM E1105 water test to check the water leakage through the supplier provided windows.

•Closely coordinate with the production/assembly and planning teams to develop production schedules and cost estimates.

•Utilize machine shop tools and machines to make working prototypes using CNC programming and CAM operations.

•Perform visual inspections using calipers, micrometer, CMM and optical comparator.

Mechanical Engineer (Freelance) Dec‘19-July’20 Forged Droids – Tempe, AZ

•Conceptualized the design and modeled rovers on Inventor for food delivery (outdoor) and UVC disinfection (indoors).

•Designed Battery Management System (BMS) for the power supply of the rover.

•Performed calculations for the selection of hovercraft motor and wheels.

•Implemented Design for additive manufacturing, Design for sheet metal, and Design for assembly for an optimized design.

•Performed simulated stress analysis to test for loading.

Mechanical Engineer (Contract) April‘19-August’19 Atom Innovation + Product Development – Scottsdale, AZ

•Developed new technology plastic part designs, SolidWorks drawings to meet all requirements for performance, reliability, cost and manufacturability of new or existing products for compression & injection molding processes.

•Conceptualized and prototyped parts by cutting foams, wood, and sheet metal at machine shop using mill, lathe, drill press, using power tools and soldering to integrate PCBs for the electromechanical systems.

•Utilized Arduino microcontroller for screen outputs. Understanding of light pipes, motors, sensors and electric circuitry.

•Assisted with outside vendors and contract manufacturers, inventory management and planning.

Specialist at Fulton 3D Printing & Laser Cutting Lab January‘19-May’19 Arizona State University – Tempe, AZ

•Evaluated customer requirements, analyse 3D CAD data and optimize it to carry out standard 3D Printing projects.

•Managed projects: Analyzed and then effectively strategize regarding business goals, deadlines, schedules, budgets, needed resources, and team member coordination.

Mechanical Engineer Intern May 2018 - August 2018

The Hillman Group – Tempe, AZ

•Designed & developed Test fixtures and systems (based on Design for Manufacturing (DFM) and Design for Assembly (DFA)) on SolidWorks for prototyping, revised Engineering drawings, models, and BOMs by approved Engineering Change Orders (ECO), and conducted Stress Analysis FEA simulation study on plastic parts to be injection molded.

•Implemented results of design of experiment (DOE) to assign optimised strategy of 40% lesser assembly time and 45% lesser packaging time.

•Implemented 6S, lean systems methodology for continuous improvement at manufacturing work environment.

•Resolved product design fault using Root Cause Analysis (5 Whys’ & Ishikawa diagram), tolerance analysis, first article inspection and did troubleshooting through Statistical analysis using SPC and/or DMAIC tools.

Manufacturing & Materials Engineer August 2016 - August 2017

Arizona State University – Tempe, AZ

•Led a project team for the chassis fabrication and collaborated with pod designers, software engineers, brake and thermal engineers to compete at SpaceX headquarters for the SpaceX’s Hyperloop competition.

•Performed Root Cause Analysis (RCA) and Failure Mode & Effect Analysis (FMEA) on braking modules and shell.

•Utilized Gantt Charts for effective project planning, prepared test plans for design verification & validation, and presented project status to cross functionals teams through meeting minutes, design reviews.

•Performed hands-on prototyping and testing on sheet metal and plastics through welding, milling, and wood working.

Mechanical Design Engineer June 2013 – June 2014

HLE Engineers Pvt Ltd, Navsari, Gujarat

•Designed pressure vessel type filter equipment in compliance with FDA regulatory standards.

•Improved and optimised critical components and fixtures using FEA simulations.

•Applied Root Cause Analysis, Risk Analysis, DFMEA, ISO standards procedures on new equipment development.

•Applied working knowledge of GD&T based on ASME Y14.5-2009 regulation and created & released drawings, BOMs.


Graduate Thesis Research & Development Dec 2017 - Dec 2018

Arizona State University – Tempe, AZ

•Researched on Design Fabrication & Characterization of Polymer Nanocarbon composite fibers.

• Focused on enhancing mechanical & thermal properties of the manufactured composites.

• Tested and analyzed internal structure and surface through SEM, measured crystallinity through WXRD, did thermal analysis with DSC and TGA and utilized tensile testing equipment for tensile strength and modulus measurements.

• Designed new spinneret which was a one stop solution to create multi-phase continuous fibers and has the ability to control nanoparticles morphology.

• Results showed an increase of 74% for the tensile modulus and 18% for the Tensile strength of the 3 phase fibers over neat polymer fibers.

•Coauthored paper “In situ alignment of graphene nanoplatelets in poly(vinyl alcohol) nanocomposite fibers with controlled stepwise interfacial exfoliation”; Nanoscale Adv., 2019, 1, 2510. DOI: 10.1039/c9na00191c

Wind Mill Blade Design Optimization for Force and Torque values

Arizona State University – Tempe, AZ Jan2017-April 2017

•Optimized wind mill blade design by simulating wind forces via CFD on ANSYS.

•Utilized different angles of attack values to measure the optimized force and torque values which reduced by 35% and increased by 40% respectively.

Anthropomorphic Robot arm Analysis Aug 2016- Dec 2016 Arizona State University – Tempe, AZ

• Analyzed an anthropomorphic Robot arm to map its workspace, plan its trajectory, MATLAB calculations using Linear Algebra for the Forward Kinematics, Inverse Kinematics, Statics & Dynamic forces on joints & its control systems.

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