Rajesh K

Mechanical Design Engineer with 8+ years of experience owning and executing medium to high complexity mechanical and electromechanical sub-system projects from concept through productization. Expert in CAD for part modelling, sheet metal design, assembly, and GD&T-compliant detailed drawings. Strong background in DFMEA, PFMEA, tolerance stack-up analysis, and structured problem solving (8D, RCA, 5-Why) to identify and mitigate design risks.

Proven ability to collaborate with cross-functional teams and suppliers to drive designs from concept through validation, manufacturing, and production release.

Experience in precision mechanical packaging and environmental sealing (IP65/IP67) relevant to high-reliability systems.

Lead Mechanical Design Engineer at Fasal (Wolkus Technology Pvt Ltd) (2025-03 – Present)

• Own and execute medium to high complexity mechanical and electromechanical sub-system projects; define system architecture including enclosure, mounting structure, thermal management strategy, and assembly approach from concept through production release.
• Design IP65 and IP67-rated plastic enclosures for outdoor electronics hardware; specify gasket material, groove geometry, compression tolerances, and sealing face requirements; validate compliance through IEC 60529 testing on T1 and T2 samples — applicable to environmental sealing requirements in semiconductor equipment enclosures.
• Perform thermal analysis of electronic enclosures to evaluate heat dissipation, airflow paths, and temperature distribution, validate performance under worst-case ambient conditions.
• Lead DFMEA activities for plastic and sheet metal designs; identify failure modes, perform risk prioritization (RPN), and drive design improvements using structured problem solving (RCA, 5-Why) prior to design release.
• Develop and review PFMEA for sheet metal fabrication and injection moulding processes in collaboration with manufacturing and CM teams; ensure PFMEA findings reflected in control plans and inspection documentation.
• Apply GD&T (ANSI Y14.5) and conduct tolerance stack-up analysis on critical assembly interfaces to ensure dimensional conformance before production release.
• Manage PPAP for new components: review dimensional results, material certifications, PFMEA, and control plans before approving suppliers for production supply; work with suppliers to ensure parts manufactured in accordance with performance and cost objectives.
• Design product packaging for transport and field deployment; define shock and vibration protection requirements, specify foam inserts and corrugated carton structure, and validate packaging through drop and vibration testing protocols.
• Develop and manage mechanical BOM in SAP PDM and Teamcenter; manage ECO and ECN processes — update 3D models and drawings in Creo, raise changes in PDM, obtain cross-functional approvals, and confirm implementation at CM with updated BOM and part numbers.
• Conduct ageing and environmental validation testing including temperature cycling, UV exposure, salt fog, and humidity testing; document results and drive design changes before production release.
• Lead cross-functional engineering team of 3+ engineers; drive culture of rigorous design quality and continuous improvement achieving 20% improvement in product reliability and 15% reduction in design cycle time.

Senior Product Development Engineer and Technical Lead at Fasal (Wolkus Technology Pvt Ltd) (2022-10 – 2025-02)

• Redesigned existing product reducing child part count by 35% and simplifying assembly process through DFM and DFA reviews, design optimisation, and iterative 3D prototype testing.
• Reverse engineered an outsourced product delivering a superior design with 10% fewer parts and 20% faster assembly time using structured design optimisation and 3D prototyping.
• Coordinated with injection mould toolmakers to develop tooling concepts, review Moldflow analysis, specify textures and surface finishes, and manage T1 through production approval; resolved tooling issues with root cause analysis and ECR documentation.
• Managed FDM and SLA rapid prototyping workflows for design validation prior to tool cutting; used prototype characterisation results to reduce T1 revision cycles and accelerate production release.
• Developed and executed feasibility studies and test plans to characterise design performance; achieved 12% cost reduction through DFM optimisation, material substitution, and tool consolidation.

Mechanical Design Engineer — Consumer Electronics and Portable Device Design at iTriangle Infotech Pvt Ltd (2018-09 – 2022-09)

• Delivered 8 injection moulding product development projects for consumer electronics and automotive products including GPS tracking enclosure; managed full lifecycle from concept through production release including tooling, DFM review, and supplier qualification.
• Designed mechanical packaging for dashcam product integrating LCD display and dual camera modules; performed cable routing within plastic enclosure to meet assembly and reliability requirements.
• Designed and built 72 pogo-pin production test jig for 4G chip firmware flashing; defined pogo-pin layout to match chip pad geometry, designed jig body in SolidWorks, and validated contact reliability through iterative prototype testing — enabling reliable high-volume firmware programming at CM and demonstrating precision assembly design capability.
• Collaborated with toolmakers to define tooling concepts, review and comment on tool designs, coordinate Moldflow analysis, and manage sample approval from T1 through production; documented tool modifications via formal ECN and ECR process.
• Conducted prototype validation using FDM and SLA 3D printed parts and injection moulded samples; performed functional, dimensional, and drop testing to verify design intent before production release.
• Travelled to contract manufacturer and component supplier sites in China for vendor qualification, tooling reviews, T1 sample review, and component procurement; coordinated directly with Asian CM partners on design and production issues.
• Produced GD&T-compliant engineering drawings, assembly instructions, and BOMs in SolidWorks; maintained records in PDM systems with full ECN and ECR change management per Engineering Change Management Process.
• Manage PPAP for new components: review dimensional results, material certifications, PFMEA, and control plans before approving suppliers for production supply; work with suppliers to ensure parts manufactured in accordance with performance and cost objectives.
• Design product packaging for transport and field deployment; define shock and vibration protection requirements, specify foam inserts and corrugated carton structure, and validate packaging through drop and vibration testing protocols.
• Develop and manage mechanical BOM in SAP PDM and Teamcenter; manage ECO and ECN processes — update 3D models and drawings in Creo, raise changes in PDM, obtain cross-functional approvals, and confirm implementation at CM with updated BOM and part numbers.
• Conduct ageing and environmental validation testing including temperature cycling, UV exposure, salt fog, and humidity testing; document results and drive design changes before production release.
• Lead cross-functional engineering team of 3+ engineers; drive culture of rigorous design quality and continuous improvement achieving 20% improvement in product reliability and 15% reduction in design cycle time.

Bachelor of Engineering in Automotive Engineering Technology – B V B College of Engineering and Technology (2013 – 2017)