Reginald Elvis

I'm a Mechanical Design Engineer with over 8 years of experience in advanced manufacturing, process optimization, and simulation-driven product development. My journey spans across cutting-edge domains like Additive Manufacturing (AM), Design for AM, and computational design—driven by a strong foundation in CAD, simulation tools, and hands-on engineering.

I specialize in developing cost-efficient, high-performance designs by leveraging technologies such as topology optimization, generative design, and lattice structures. My work has consistently focused on translating complex engineering challenges into scalable, validated solutions through rigorous testing and data analysis.

Throughout my career, I’ve thrived in R&D-intensive environments where cross-functional collaboration and innovation are key. I'm passionate about bridging the gap between design and manufacturing, ensuring that every concept is both functional and production-ready.

Whether it's optimizing parts for aerospace or building algorithms for advanced 3D printing workflows, I enjoy working at the intersection of design, simulation, and real-world performance.

eginald Elvis is a seasoned Mechanical Design Engineer with over 8 years of experience specializing in advanced manufacturing, design optimization, and additive manufacturing (AM). His expertise spans across academia and industry, with significant contributions in simulation-driven design, topology optimization, product development, and process parameter optimization for metal AM.

Current Role

Team Lead, Intech Additive Solutions Pvt. Ltd. (2023–Present)

Leads end-to-end development of software tools for metal AM, including support automation, process mapping, and topology optimization.

Manages cross-functional teams and drives algorithm development aligned with aerospace industry standards.

Enhances design for manufacturability and reduces post-processing needs via customized solutions.

Previous Roles

Senior Software Engineer, Intech Additive Solutions

Designed algorithms for process and cost optimization in additive and subtractive manufacturing.

Integrated AM constraints into topology optimization workflows and validated R&D solutions.

Research Scholar, IIITDM Kancheepuram (2017–2024)

Mentored students in design and manufacturing, led projects on smart manufacturing, and worked on simulation tools like Arena.

Conducted applied research on hybrid AM, support structure optimization, and DED process modeling.

Guest Faculty, BITS Pilani – WILP (2019–2021)

Trained 300+ industry professionals in AM technologies and DfAM principles using industry-standard software tools.

Teaching Assistant, Teaching Learning Centre (2018–2024)

Delivered hands-on training in 3D printing and CNC machining to students at various educational levels.

Core Competencies

Topology Optimization, Generative Design, Lattice Structures

LPBF and DED Process Development

Mechanical Design & CAD/CAE Tools: Fusion360, SolidWorks, ANSYS, CATIA, nTop

Programming: Python, MATLAB, CPP

Project Management, Technical Writing, Quality Systems

Ph.D. in Mechanical Engineering

Indian Institute of Information Technology, Design & Manufacturing (IIITDM), Kancheepuram

2017 – 2024

GPA: 8.75

Focused on Additive Manufacturing (AM), Design for Manufacturability, Process Optimization, and Topology Optimization.

Conducted cutting-edge research in hybrid AM, process parameter tuning, support structure optimization, and part qualification for aerospace applications.

M.E. in Manufacturing Engineering

ACCET, Karaikudi (Anna University)

2011 – 2013

CGPA: 8.985

Specialized in Advanced Manufacturing Processes and Welding Parameter Optimization.

Completed a thesis on weld bead geometry using P-GMAW.

B.E. in Mechanical Engineering

Anna University, Chennai

2007 – 2011

GPA: 80.59%

Developed a strong foundation in mechanical systems, design principles, and materials engineering.