Experience

Studied about compliant mechanisms and precision engineering fundamentals, completing the NPTEL coursework Design of Precision Machines by Prof. J.P. Khatait (IIT Delhi) to build the theoretical foundation required for the research.

Developed a precision displacement sensor targeting micron-level (10⁻⁶ m) accuracy by systematically analyzing mechanical strain patterns and material deformation characteristics under controlled displacement.

Implemented MATLAB-based data visualization to map strain–displacement behaviour, derived theoretical formulations from first principles, and validated them against experimentally observed correlations — closing the loop between analytical models and physical results.

Successfully built a functional Precision Displacement Sensor, and continuing to refine it post-internship, actively working to further reduce noise and improve repeatability.

Worked on the prototype development of the brake pedal assembly for Surge 32 - a convertible 2-in-1 electric vehicle project by Hero MotoCorp. My primary contribution was generating production-ready manufacturing drawings for the assembly components, specifying dimensions, tolerances, and surface finish requirements so operators could accurately produce parts on the lathe and laser cutting machine before welding them into the final assembly.

Beyond drawing work, I also got hands-on time on the shop floor where I personally performed operations including grinding, buffing, rolling, and drilling. Combined with observing the full fabrication sequence i.e. laser cutting, lathe turning, and welding, this gave me a practical understanding of how drawing decisions translate to real manufacturing challenges, and what machinists need from a drawing to work efficiently and accurately.

This internship taught me the importance of the design-to-manufacturing handoff. I learned that a good drawing isn't just geometrically correct, but also unambiguous, manufacturable, and anticipates the questions an operator might have on the shop floor.

During the internship I worked on multiple mechanical assemblies and product designs across different client requirements, with one of the primary deliverables being a water-resistant PCB enclosure with an O-ring groove sealing system targeting IP67 compliance i.e. 1m immersion and dust protection. The O-ring compression was held between 20–25% by carefully sizing the groove depth relative to the O-ring cross-section diameter. Below 20% compression the contact force is insufficient to block water ingress, and above 30% the rubber permanently deforms and loses its sealing ability over time. Getting this range right required tolerance stack-up analysis across all mating dimensions to ensure every manufactured unit, not just the ideal design, stayed within the functional window.

Benchmarked 10+ existing tracking and IoT devices to identify gaps which led to identifying 3 distinct user segments that modular attachment extensions could serve.

Translated conceptual briefs from wearenotice.com into 5+ manufacturable designs for aesthetic home decor products.

Gained hands-on experience with the full mechanical design process, from customer requirements and competitive benchmarking, through tolerance analysis and DFM, to production-ready drawings and design reviews. This internship built my understanding of how small dimensional decisions at the design stage directly impact whether a product functions reliably in the real world.

I led a 7-member chassis sub-team within a 50+ member vehicle team, holding full ownership of the department. Every design call, fabrication decision, and procurement choice ran through me.

Modeled the complete spaceframe in CAD, supervised the chassis fabrication and composite body manufacturing, while overseeing complete vehicle assembly of Arka.

Delivered a competition-ready vehicle for BSVC 2025, Coimbatore, achieving a 35% reduction in drag coefficient (Cd) validated through iterative CFD, while managing procurement, two parallel fabrication workstreams, and a 7-member sub-team within a 50+ member team.

I walked into this project without having fabricated anything beyond a college lab assignment. I walked out having managed a full engineering sub-system end-to-end from material spec to vehicle on track. Every constraint (budget, time, tools) forced creative problem-solving. Leading a team through months of ambiguity, while staying hands-on myself, is the part of this experience I'm most proud of.