Electro-Mechanical Design & Development Portfolio
An interactive guide to Low-Voltage Switchgear, Tool Design, and advanced engineering principles, showcasing a commitment to innovation and quality.
My Engineering Journey
💼 Experienced Mechanical and Electrical Engineer specializing in the design and development of Low Voltage (LV) switchboards and sheet metal components. Proficient in adhering to IEC 61439 standards, optimizing linkage systems for Air Circuit Breakers (ACB) and Molded Case Circuit Breakers (MCCB) using Creo Parametric and AutoCAD, and performing stress analysis with Ansys and Creo Simulation.
🚀 As a Lead Designer, I spearhead product development initiatives, incorporating mechanical and electrical engineering principles to enhance functionality, compliance, and performance. Skilled in generating precise 2D drawings, developing Bills of Materials (BOM), and using SAP for comprehensive documentation and tracking. My expertise extends to designing aesthetically pleasing, forward-thinking panels using Keyshot for high-quality renderings.
🔧 I excel in creating 3D CAD models and detailed 2D drawings, collaborating with cross-functional teams to meet quality standards, cost targets, and production schedules. I troubleshoot and resolve design issues, maintain detailed design records, and stay current with industry advancements to continuously improve processes and product quality.
Professional Experience
Research And Development Engineer
SES SAMA AL EMIRATES (ABB) | United Arab Emirates | April 2025 - Present
- Lead R&D initiatives for next-generation electromechanical products, utilizing SolidWorks, Creo, and Inventor for complex 3D modeling and technical documentation.
- Apply DFMEA and FTA methodologies to proactively identify and mitigate design risks, enhancing product reliability and safety.
- Conduct advanced FEA simulations for structural and thermal analysis to optimize designs and validate performance against industry standards.
Research And Development Engineer
Flex (Contract via L&T Technology Services) | India, Remote for United States Client | January 2025 - April 2025
- Developed intricate 3D part and assembly models using SolidWorks, Creo, and Inventor, applying a holistic approach to mechanical and electrical engineering principles.
- Leveraged parametric design, surface modeling, and specialized sheet metal modules to translate complex concepts into production-ready designs.
Research And Development Engineer
Schneider Electric | Navi Mumbai, India | November 2023 - January 2025
- Designed and developed Low Voltage (LV) switchboards compliant with IEC 61439, focusing on performance, manufacturability, and aesthetic appeal.
- Engineered and optimized linkage systems for Air Circuit Breakers (ACB) and Molded Case Circuit Breakers (MCCB) using Creo Parametric, validating designs with Creo Simulation and Ansys.
Jr. Engineer (Tool Design)
Connectwell Industries Pvt. Ltd | Dombivli, India | December 2022 - November 2023
- Designed complex plastic injection molds and die-casting molds based on product specifications.
- Created detailed 3D models and 2D manufacturing drawings for mold components, jigs, and fixtures.
Tool & Dies Design Engineer (Advance Trainee)
Larsen & Toubro | India | August 2020 - December 2022
- Designed and developed tools, dies, and molds for various manufacturing processes including stamping, forging, and casting.
- Programmed CNC EDM machines and interpreted engineering drawings to define machining requirements.
Core Competencies
CAD/CAE Software
SolidWorks, Creo Parametric, Autodesk Inventor, Solid Edge, Ansys, Creo Simulation, AutoCAD, Keyshot
Engineering Methodologies
DFMEA, FTA, FMEA, Finite Element Analysis (FEA), DFM, DFA, DFS, Poka-yoke, Gemba, 5S, DMAIC
Technical Skills
Product Development, Electromechanical Systems, Sheet Metal Design, Plastic Injection Molds, Die-Casting, LV Switchboards, Power Distribution Boards (PDBs), GD&T, Prototyping, Testing & Validation
DFMEA / FMEA (Failure Mode and Effects Analysis)
Definition: A systematic, proactive method for evaluating a process or design to identify where and how it might fail and to assess the relative impact of different failures.
Example: Analyzing a new MCCB linkage mechanism to identify potential failure modes like jamming or material fatigue, assessing their severity, and implementing design changes (e.g., stronger material, redundant springs) to mitigate high-risk failures before prototyping.
FEA (Finite Element Analysis)
Definition: A computerized method for predicting how a product reacts to real-world forces, vibration, heat, and other physical effects.
Example: Simulating the electromagnetic forces on a busbar during a 50kA short-circuit event to verify that the structural supports will not break and that deflection remains within safe electrical clearance limits.
DFM / DFA (Design for Manufacturability / Assembly)
Definition: The practice of designing products to be easy to manufacture and assemble, reducing costs and improving quality.
Example: Redesigning a sheet metal enclosure to use self-clinching fasteners instead of welded nuts, which simplifies the assembly process, reduces labor time, and eliminates a separate welding operation.
Poka-yoke
Definition: A Japanese term for "mistake-proofing," a mechanism in a process that helps an operator avoid (yokeru) mistakes (poka).
Example: Designing a plastic insulator with an asymmetrical mounting hole pattern so it can only be installed in the correct orientation, preventing incorrect assembly on the factory floor.
DMAIC
Definition: A data-driven quality strategy for improving processes, standing for Define, Measure, Analyze, Improve, and Control.
Example: Using the DMAIC framework to address a high defect rate in a panel assembly line. **Define** the problem, **Measure** the current defect rate, **Analyze** the root causes (e.g., tolerance stack-up), **Improve** the design by modifying component tolerances, and **Control** the new process with updated drawings and quality checks.
The Design & Development Process
Designing for Sheet Metal
- Requirements Gathering: Define structural loads, environmental conditions (IP rating), thermal dissipation needs, and applicable standards (IEC 61439).
- Material Selection: Choose between CRCA, GI, SS, or Aluminum based on corrosion resistance, strength, weight, and cost requirements.
- Structural Design & FEA: Model the enclosure in 3D CAD. Perform FEA to simulate short-circuit forces and ensure structural integrity of the frame, doors, and busbar supports.
- Design for Manufacturability (DFM): Optimize the design for factory processes. Standardize bend radii, define hole sizes for standard tooling, and select appropriate fastening methods (welding, riveting, self-clinching fasteners).
- Flat Pattern Generation: Create accurate 2D flat patterns from the 3D models, applying the correct K-Factor for the material and thickness to ensure precise final dimensions after bending.
- Prototyping & Testing: Build and assemble a physical prototype to verify fit, form, and function. Conduct type-tests for IP rating, mechanical impact, and temperature rise.
Designing for Molded Plastics
- Requirements Gathering: Define electrical properties (dielectric strength, CTI), mechanical loads, thermal exposure (RTI), and flammability rating (UL 94).
- Polymer Selection: Choose the optimal thermoplastic (PC, PA, PBT) or thermoset (GPO-3, BMC) based on the performance requirements matrix.
- Part Design & DFM: This is the most critical phase. Design the part with uniform wall thickness. Apply draft angles (1-2°) to all vertical faces. Add ribs (at 50-60% of wall thickness) for strength, not thickness. Design bosses with proper gussets.
- Mold Flow Analysis: Simulate the injection molding process to predict how plastic will fill the mold cavity. Identify potential issues like weld lines, air traps, or sink marks and modify the design to correct them.
- Tooling Design: Design the steel mold, defining the parting line, gate locations, ejector pin layout, and cooling channels. This is a collaborative process with a toolmaker.
- Prototyping & Validation: Produce first-off-the-tool (FOT) samples. Perform detailed dimensional analysis and functional testing to validate that the part meets all specifications before mass production.
Design Fundamentals
An overview of critical materials and principles for robust design in switchgear and tooling, focusing on performance, safety, and manufacturability.
Material Selection for Tool & Enclosure Design
Enclosure & Structural Materials (Metals)
| Material | Key Properties | Primary Application |
|---|---|---|
| Mild Steel (CRCA) | High strength, excellent formability, smooth finish. Requires coating. | Standard indoor switchgear enclosures. |
| Galvanized Steel (GI) | Good strength with inherent corrosion resistance from zinc coating. | Outdoor enclosures, high-humidity environments. |
| Stainless Steel (SS 304) | Excellent corrosion resistance, good strength. | Food processing, pharmaceutical, and chemical plants. |
| Stainless Steel (SS 316) | Superior corrosion resistance, especially against chlorides. | Marine environments, coastal installations. |
| Aluminum (5052/6061) | Lightweight, high thermal conductivity, good corrosion resistance. | Weight-sensitive applications, heat dissipation plates. |
Insulating & Mechanical Materials (Polymers)
| Material | Key Properties | Primary Application |
|---|---|---|
| Polycarbonate (PC) | High impact strength, optical clarity, good dielectric strength. | Breaker housings, viewing windows, safety covers. |
| Polyamide (PA66-GF30) | High mechanical strength, stiffness, and wear resistance. | Levers, actuators, mechanical linkages, connectors. |
| PBT-GF30 | Excellent dimensional stability, high CTI, good heat resistance. | Precision electrical components, coil formers, bobbins. |
| GPO-3 (Glass Polyester) | Excellent arc & track resistance, high mechanical strength. | Busbar supports, phase barriers, standoff insulators. |
| ABS | Good toughness and rigidity, cost-effective. | Non-critical housings, covers, and internal panels. |
Tool Steels for Molds & Press Tools
| Material | Key Properties | Primary Application |
|---|---|---|
| OHNS (Oil-Hardening) | Good balance of hardness & toughness, minimal distortion. | Blanking/piercing dies, gauges, short-run mold inserts. |
| P20 | Pre-hardened, excellent polishability, good machinability. | Industry standard for plastic injection mold cores and cavities. |
| H13 | High hot hardness, good toughness, resists thermal fatigue. | Die-casting dies, extrusion dies, forging dies. |
| D2 | High carbon, high chromium; excellent abrasion resistance. | Long-run stamping dies, forming rolls, cutting tools. |
Get in Touch
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I'm always open to discussing new projects, creative ideas, or opportunities to be part of an innovative team. Feel free to reach out.
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