Projects
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Headlight Leak-Test Station
Client: car manufacturer, India Role: Mechanical Design Engineer Duration: 4 months
Tools Used: SolidWorks | ANSYS | AutoCAD | Pneumatic Design
Objective
To design and develop a leak-test station with four interchangeable (change-over) fixtures and one main pneumatic testing unit for verifying the sealing performance of automotive headlights.
Key Responsibilities
Designed modular fixture assemblies allowing quick changeovers for testing four different headlight variants.
Created 3D CAD models, assembly layouts, and fabrication drawings for the main station and all fixtures using SolidWorks.
Developed pneumatic circuits integrating pressure regulators, valves, and flow sensors to ensure repeatable test accuracy.
Conducted FEA and flow analysis in ANSYS to validate fixture rigidity and sealing force.
Collaborated with the electrical and control teams to integrate PLC-based automation, control panel wiring, and safety interlocks.
Prepared BOMs, part lists, and installation guides following ASME drafting standards.
Results / Impact
Delivered a multi-fixture leak-test system reducing setup time by 30% through modular design.
Achieved leak detection repeatability within ±0.5%, meeting Volkswagen’s QA standards.
Improved maintenance efficiency and minimized downtime by enabling tool-free fixture swaps.
Main station
1 out of 4 Interchangeable (change-over) Fixture.
Example of 2D drafting and Drawings
Petrol Fuel Tank Leak-Test Rotary Station
Client: car manufacturer, India Role: Mechanical Design Engineer Duration: 5 months
Tools Used: SolidWorks | ANSYS | Pneumatic Design | PLC Integration
Objective
To design and develop a rotary-type leak-test station capable of simultaneously testing four fuel tanks for leakage and pressure integrity, ensuring high throughput and operator efficiency on the assembly line.
Key Responsibilities
Designed the complete rotary leak test station framework, incorporating 4 fixture positions for concurrent fuel tank testing.
Created 3D CAD models and detailed fabrication drawings for structural frames, rotary mechanisms, and pneumatic sealing modules.
Developed rotational indexing system with precise alignment and fixture locking for leak integrity.
Integrated pressure sensors, regulators, and PLC control interfaces for automated leak-test sequencing.
Performed stress and pressure validation in ANSYS to ensure fixture rigidity and repeatability.
Delivered full BOM, pneumatic schematics, and installation documentation aligned with manufacturing standards.
Results / Impact
Increased production efficiency by 40% through parallel testing of multiple tanks.
Achieved leak detection accuracy within ±0.3%, exceeding client specifications.
Reduced operator fatigue and handling time using ergonomic rotary indexing design
Main station
4 Different Fuel tank with Fixture.
DAP with PPT file for rotary leak test station
Go-Kart Design and Simulation
Type: Academic / Personal R&D Project Role: Mechanical Design Engineer Duration: 6 months
Tools Used: SolidWorks | ANSYS (Structural & Thermal) | AutoCAD
Objective
To conceptualize, design, and analyze a go-kart vehicle integrating performance, safety, and manufacturability considerations. The project focused on lightweight chassis design, crash impact simulation, and thermal performance evaluation of the braking system.
Key Responsibilities
Developed the complete 3D CAD model of the go-kart, including chassis, steering, braking, and drivetrain assemblies.
Conducted structural crash analysis of the chassis using ANSYS to ensure driver safety under frontal impact conditions.
Performed thermal simulation of the disc brake to evaluate temperature distribution and optimize heat dissipation.
Applied DFM principles for manufacturability and material optimization (mild steel, AISI 4130).
Created detailed 2D fabrication drawings and assembly manuals with GD&T standards.
Results / Impact
Achieved 15% weight reduction while maintaining safety factors above design threshold.
Validated chassis crashworthiness using finite element analysis.
Optimized brake disc performance, reducing peak temperature rise by 12% during continuous braking cycles.
Go-kart
Brake Disk Thermal Analysis (Ansys)
Chassis Crash test simulation with PDF file