Design Engineer Product

CHARAN SAI BANDARU

****************@*****.*** 323-***-**** Sunnyvale, CA LinkedIn Portfolio SUMMARY

Highly innovative Mechanical Product Design Engineer (MS degree) with 4 years of practical experience across the full product design lifecycle, from requirements gathering and concept generation to detailed design, advanced analysis, and manufacturing release and platforms. Expertise in designing and optimizing complex electro-mechanical assemblies, liquid cooling systems, plastic/metal components (sheet metal, injection molding), and printed circuit boards/flexes. Proficient in advanced CAD (NX, SolidWorks, CATIA, Creo) and FEA (Ansys, Abaqus) for structural and thermal analysis, alongside mechanical tolerance analysis. Proven ability to troubleshoot, root cause, and resolve technical issues, drive innovation, and make data-driven decisions. Experienced in PLC programming (Allen Bradley, Siemens), sensor configuration, and Python/C++ automation for control system development and test sequence automation. Skilled in cross-functional project management, Lean Six Sigma methodologies, and collaborating with contract manufacturers and suppliers to drive root cause analysis and continuous process improvements.

EXPERIENCE

Product Design Engineer - NASA L'SPACE (Aug 2024 - Feb 2025)

• Led concept-to-prototype development of thermal management hardware, leveraging CFD simulation and IIoT sensors for critical performance validation.

• Designed and validated custom embedded electronic sensor modules for space-grade testing workflows, automating edge data collection and ensuring PCBA manufacturing process validation.

• Collaborated cross-functionally with manufacturing teams to ensure DFM/DFA compliance for medium-scale production, refining hardware designs for robust and scalable deployment.

• Created comprehensive BOMs, SOPs, and integration guides for prototype delivery and hardware documentation, supporting NPI processes. Graduate Research Assistant - Arizona State University (Jan 2023 - Jul 2024)

• Designed and simulated airflow test rigs with PLC-based edge controllers using Emulate3D and LabVIEW, optimizing system performance.

• Executed advanced computational thermal/mechanical simulations (FEA/CFD) and stress and tolerance analysis to analyze and improve hardware thermal performance and structural integrity, ensuring designs met stringent requirements.

• Programmed and integrated electronic control logic for custom validation fixtures, interfacing with depth and vibration sensors, directly contributing to acceptance testing protocols.

• Delivered analysis dashboards using Python and MATLAB to optimize operator workflow and test cycle time, enhancing manufacturing process efficiency.

• Created detailed test plans and lifecycle documents used in fulfillment-scale automation benchmarking, demonstrating experience in new line/equipment qualification.

Mechanical Engineer - TATA Advanced Systems Ltd. (Jan 2022 - Nov 2022)

• Managed hardware integration of complex embedded electronic control systems in high-speed packaging lines and avionics enclosures, gaining extensive experience with box build manufacturing processes.

• Developed PLC interfaces for mechanical motion subassemblies using Allen Bradley/Siemens logic, crucial for manufacturing process startup and control.

• Spearheaded comprehensive hardware test strategies, including vision sensor calibration and fatigue/stress testing, directly supporting PCBA manufacturing acceptance testing.

• Created and managed test plans, Python scripts, and evaluation protocols, performing hands-on testing and validation of prototype systems and sub- assemblies to meet stringent engineering requirements and conduct failure analysis.

• Collaborated extensively with manufacturing partners and field engineers to scale system deployment and maintenance cycles, driving continuous process improvements.

Mechanical Design Engineer - AEROLANCE Pvt Ltd (Sept 2020 - Dec 2021)

• Modeled structural hardware with Creo & CATIA; implemented actuator placement for robotic fixtures, contributing to Design for Manufacturing (DFM) considerations.

• Integrated and optimized edge compute devices with various electronic sensors (vibration, thermal) into high-speed automation jigs, enhancing SMT and box build assembly processes.

• Applied GD&T and conducted top-level tolerance analysis (Worst Case, RSS) for critical chip/socket/cooling solution stack-ups, ensuring optimal structural behavior and reliability.

• Developed logic flows in Python for test sequence automation and rapid part evaluation using SketchUp simulation, streamlining manufacturing validation.

• Produced field-validated 3D CADs, wiring diagrams, and component layouts for system rollout, ensuring new equipment bring-up and qualification. EDUCATION

M.S. Aerospace & Mechanical Engineering - Arizona State University, Tempe, AZ (Dec 2024) B.E. Aeronautical Engineering - Institute of Aeronautical Engineering, Hyderabad, India (Aug 2021) SKILLS & TOOLS

• Product Design Lifecycle: Requirements Gathering, Concept Generation, Detailed Design, Engineering Analysis, Verification Testing, Cross-Functional Reviews, Manufacturing Release, Innovation Opportunities, Technology Risk Identification.

• PLC & Controls: Allen Bradley, Siemens, IIoT, Sensors (Vision, Depth), Edge Compute, SCADA

• Mechanical Design Expertise: Cooling Systems (Liquid Cooling, Air-Cooled), Plastic Parts Design, Metal Parts Design (Sheet Metal, Injection Molding), Mechanical Assemblies, Printed Circuit Boards (PCBs), Flexes, Electro-Mechanical Assemblies, Compact Mechanisms Design, Chip/Socket/Cooling Solution Stack-ups, Structural Behavior.

• CAD & Analysis Tools: 3D MCAD, NX, Creo, SolidWorks, CATIA V5/V6, AutoCAD, Inventor, ANSYS, Abaqus, COMSOL, CFD, FEA, Thermal Analysis, Structural Analysis, Mechanical Tolerances, Tolerance Analysis (Worst Case, RSS), SolidWorks, AutoCAD, Creo, CATIA, NX, SketchUp.

• Testing & Validation: Test Plan Creation, Test Execution, Design Validation, Troubleshooting, Root Cause Analysis, Thermal Characterization, Lab Equipment Design/Development, NPI Lab Support, Data Analysis, Reliability Testing.

• Manufacturing Principles: Design for Medium-Scale Production, DFM, DFA, FMEA, Supplier Management, Mass Production.

• Software & Scripting: Python, MATLAB, Minitab, C++, Simulink, Tableau, Linux Environment, Shell Scripting CERTIFICATIONS

Lean Six Sigma Green Belt, DFMEA Specialist, Applied CFD, Semiconductor Packaging, GD&T, Supply Chain, Product Design Management, PCBA Packaging, Applied CAD for Consumer Electronics, CAE ABAQUS, Class A Surfacing, SCADA, Minitab, Agile Methods, Project Management, FMEA.

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