Francis Vimalan

New Product Development Engineer with expertise in mechanical design, finite element analysis (FEA), and value engineering. Skilled in developing defense and automotive components from concept to production using SolidWorks, Creo, and ANSYS. Proven track record in optimizing structural systems with advanced materials such as ARMOX 440T, ARMOX 500T, and FRP composites for lightweight and high-performance defense applications.

Senior Design Engineer - Athes Automotive Pvt Ltd - Coimbatore, India

(2025-01)

• Led design and development of multiple defense and automotive projects involving ARMOX 440T and 500T ballistic steel.
• Engineered FRP composite sandwich structures for an amphibious vehicle hull and tested them for weight optimization and impact resistance.
• Executed reverse engineering of critical tank subsystems, including control arms, CV joints, break disk, and connecting rods, to support system reconfiguration and lifecycle extension.
• Performed structural and fatigue analysis using ANSYS and Creo Simulate to validate load-bearing capability under extreme operating conditions.
• Collaborated with manufacturing and materials teams to optimize weld geometry and joint stiffness for improved structural integrity.
• Managed PLM documentation, revision control, and BOM tracking for defense-grade projects.

New Product Development Engineer - Rotary Connectors Pvt Ltd - Bangalore, India

(2024-06 - 2025-01)

• Designed and developed MIL-5015, Mighty Mouse, and MIL-DTL-83723 connectors from concept to production.
• Created 3D CAD models, tolerance stack-ups, and detailed drawings in SolidWorks ensuring MIL compliance.
• Conducted structural and modal FEA in ANSYS to evaluate fatigue performance under vibration and shock conditions.
• Utilized 3D printing for rapid prototyping and assembly validation.

Freelance Design & Structural Engineer - Upwork - Remote

(2023-12 - 2024-02)

• Delivered design and FEA projects for clients across automotive, consumer, and industrial domains.
• Developed and optimized plastic injection-molded parts for manufacturability and assembly.
• Conducted design and structural analysis of holding structures using SolidWorks and ANSYS, including load, deformation, and buckling studies.

Graduate Research Scholar - Defence Research and Development Laboratory (DRDL) - Hyderabad, India

(2023-08 - 2024-05)

• Conducted research on shape memory alloy joints for aerospace structures, published findings at NIT Warangal.
• Performed static structural, modal, and optimization analysis in ANSYS Workbench.
• Proposed actuator replacement designs improving stiffness-to-weight ratios in aerospace assemblies.

M.Tech - Defence Technology (Combat Vehicle Technology) - Amity University (2022-06 - 2024-05)

B.E - Mechatronics Engineering - Acharya Institute of Technology (2018-06 - 2022-05)

12th - Sribala Vidya Mandir Matric Hr. Sec. School (2017-06 - 2018-05)

10th - Sribala Vidya Mandir Matric Hr. Sec. School (2015-06 - 2016-05)