Sonal Chibire

Mechanical Engineer with 3+ years of experience in mechanical product design, SolidWorks, engineering analysis, testing, manufacturing support, and product improvement. Skilled in developing mechanical assemblies, drawings, BOMs, specifications, fixtures, and engineering changes while considering structural integrity, material selection, manufacturability, reliability, and cost. Experienced working independently and with distributed engineering, manufacturing, quality, sourcing, supplier, and customer teams.

Graduate Research Assistant, Dept of Mechanical Engineering at Northern Illinois University (2024-02 – 2026-04)

• Developed and validated analytical and finite element models using ANSYS, MATLAB, and Python to evaluate stress, strain, displacement, structural integrity, and dynamic response.
• Planned and executed validation studies by comparing analytical, numerical, and experimental results.
• Performed engineering calculations, sensitivity studies, data analysis to evaluate materials, geometry, loads, and interface behavior.
• Investigated performance discrepancies through root-cause analysis and recommended design and modeling improvements.
• Prepared technical reports, test summaries, presentations, and engineering documentation for multidisciplinary teams.

CAE Engineer at Denfab Engineering Consulting Ltd (2023-04 – 2023-08)

• Performed structural and thermal analysis of industrial waste-heat-boiler equipment using ANSYS Workbench.
• Evaluated temperature distribution, heat transfer, stress, deformation, operating loads, and material performance.
• Supported design optimization that improved heat-transfer performance by approximately 30%.
• Compared design alternatives and recommended improvements based on performance, reliability, and operating requirements.

Design Engineer at Dembla Valves Ltd (2022-01 – 2023-04)

• Designed and modified globe, ball, and butterfly valves, pressure-containing components, pressure-containing parts, sealing interfaces, and mechanical assemblies using AutoCAD, SolidWorks, and Creo.
• Translated customer and manufacturing requirements into defensible design decisions based on performance, materials, tolerances, cost, and production capability.
• Created 3D models, detail drawings, assembly drawings, BOMs, specifications, and engineering change documentation.
• Performed structural FEA, engineering calculations, tolerance studies, and material selection to verify strength, fit, pressure integrity, and reliability.
• Participated in design reviews and supported prototype evaluation, testing, validation, and production release.
• Investigated leakage, fit-up, tolerance, material, and field-performance failures through root-cause analysis and corrective action.
• Applied GD&T, DFM, DFA, and FMEA principles to improve manufacturability, assembly quality, reliability, and cost.
• Guided junior design engineers and reviewed their CAD models, drawings, BOMs, and design calculations.
• Ensured compliance with industry standards and technical specifications ANSI B16.34, ANSI B16.5, API 6D, API 6A, ANSI B16.10.

Assistant Professor at University of Mumbai (2021-04 – 2021-12)

• Taught FEA, Mechanical Vibrations, and Machine Learning applications in mechanical engineering

Project Intern at Apar Industries Limited (Oil & Gas Division) (2020-11 – 2021-03)

• Achieved 40% turbulence-intensity improvement and 13-17% cycle-time reduction through CFD-based impeller and baffle redesign.

Project Intern at Larsen & Toubro Heavy Engineering (2018-06 – 2018-08)

• Optimized the thickness of Hydraulic Block Manifold to reduce weight without affecting its robustness using Solidworks and Ansys workbench and validated the results from simulation with ASME-BPVC.

M.S. in Mechanical Engineering – Northern Illinois University (2024-01 – 2026-05)

Master of Engineering in Machine Design – University of Mumbai (2017 – 2019)

Bachelor of Engineering in Mechanical Engineering – University of Mumbai (2012 – 2016)