Drone Hood Enclosure
DroneShine · Freelance mechanical design
Freelance design of a protective hood for a drone platform — shaping the geometry around real aerodynamic constraints rather than just enclosure fit.
- Owned the mechanical design end-to-end: concept, CAD, and 3D-printed prototype iterations
- Iterated through physical prototypes until the new hood outperformed the original part
- Geometry driven by airflow, weight, and impact protection — not just covering the electronics
CO₂ Air-Filter Prototypes
Air-filtration startup · Reutlingen · 2025—today
Sole mechanical engineer for a photobioreactor-based CO₂ air filter — from first concept sketch to passed product validation, across two size classes (3 L and 15 L).
- Full mechanical design in SolidWorks: sealed fluid volume, light-exposure geometry, serviceable access
- Rapid prototyping via 3D printing; iterative test cycles with structured test planning & documentation
- 15+ parts and assemblies to GD&T with production-ready drawings; complete BOM/PLM dataset for series transition
Environmental Chamber Simulation
Weiss Technik GmbH · Master's thesis · 2024
Extension and validation of a chamber simulation tool (CST) for environmental test systems with CO₂ refrigeration technology.
- Thermodynamic model in MATLAB/Simulink — deviation vs. real measurement data reduced to under 3%
- 40+ simulation runs across pressure, temperature, and mass-flow distributions in HVAC refrigeration circuits
- Coordinated three departments and external suppliers; requirements analysis via SAP ERP
Axial-Flux Motor Components
Mercedes-Benz AG · E-drive pre-development · 2023—24
Component design and simulation in electric drivetrain pre-development — where CAD decisions meet series-production reality.
- Axial-flux motor components in Siemens NX with rotor-dynamics simulation — results fed into series decisions
- Cohesive-zone models in ABAQUS for adhesive joints, calibrated against experimental data
- Python-automated simulation workflows (~30% less manual time); DoE optimization across 50+ variants (HEEDS)
Visuals under NDA — methodology happily discussed in conversation.
Electric Two-Wheeler — Team ECO RIDERS
SAEISS ETWDC 2019 · Team captain & design lead
A road-ready electric two-wheeler designed, built, and raced by the 10-person student team I led — 7th place nationally in India.
- 48 V BLDC hub motor, Li-ion pack, ~70 km range; chassis modelled in SolidWorks/CREO
- Static structural, modal, and harmonic-response FEA in ANSYS — 37k-node mesh, real rider load cases; findings drove iterative frame redesign (~12% lighter at unchanged stiffness)
- Delivered on time for two national SAE competitions, with full design & FEA documentation
