Arnav Mehta
Design Engineer Intern
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About
Commissioned an embedded controller board for a high-current motor test stand, paralleling H-bridge drivers to distribute stall current and validating the platform end-to-end with zero fault transients. Developed a Simulink-based BLDC motor-drive application with real-time current sampling, closed-loop control, and CAN telemetry, auto-generating production-ready code for the Husco HCM off-highway controller. Built an agentic LLM workflow that converts natural-language requirements into validated controller code through automated model synthesis, compressing the requirement-to-firmware cycle.
Experience
Design Engineer Intern - HUSCO International - Waukesha, WI
(2026-05 - 2026-07)
- Commissioned an embedded controller board for a high-current motor test stand, paralleling H-bridge drivers to distribute stall current and validating the platform end-to-end with zero fault transients.
- Developed a Simulink-based BLDC motor-drive application with real-time current sampling, closed-loop control, and CAN telemetry, auto-generating production-ready code for the Husco HCM off-highway controller.
- Built an agentic LLM workflow that converts natural-language requirements into validated controller code through automated model synthesis, compressing the requirement-to-firmware cycle.
Design Engineer Co-op - HUSCO International - Waukesha, WI
(2025-05 - 2025-12)
- Engineered and validated Variable Force Solenoid (VFS) assemblies for Ford, GM, and BMW programs, coupling electromagnetic, thermal, and structural multi-physics simulation to maximize force density.
- Correlated Ansys Maxwell predictions with force-stroke and dynamic test data to within <3% deviation, then raised product reliability 12% through DOE and accelerated durability testing.
- Ran tolerance stack-up and Monte Carlo analyses and set GD&T, surface-finish, and material specifications to guarantee supplier manufacturability and automotive quality compliance.
Maintenance Engineer Intern - Polyplex USA LLC - Decatur, AL
(2024-06 - 2024-08)
- Repaired and restored industrial fluid and thermal systems — pumps, motors, gearboxes, and heat-exchange networks — improving plant uptime 8%.
- Partnered with OEMs (Bobst, Siemens, Kampf) to design and deploy production-line modifications and layout improvements on schedule and within budget.
Drivetrain & Data Acquisition Vice President - Baja SAE, UW–Madison - Madison, WI
(2023-09)
- Leading development of an electronic CVT (e-CVT) with closed-loop control, real-time feedback, and PWM actuation to optimize torque delivery and drivetrain efficiency.
- Validated the drivetrain via torque-path simulation, kinematic modeling, and strain instrumentation, improving load-bearing capacity 20% through geometry refinement and FEA correlation.
- Fabricated assemblies with multi-axis CNC, manual lathe/mill, and TIG welding to SAE Baja DVP&R standards, contributing to a 2nd-place Endurance finish against international teams [confirm event & year].
Undergraduate Researcher - HERD Lab, UW–Madison - Madison, WI
(2024-01)
- Rebuilding a Solid Oxide Electrolysis Cell (SOEC) test station with simultaneous, independent control of temperature gradient, steam concentration, and current density while preserving real-time optical access to the Ni-YSZ microstructure.
- Designed and fabricated custom hardware for high-precision mass-flow control with real-time data logging.
Education
B.S. - Mechanical Engineering - University of Wisconsin–Madison (2026-12)
