Global rank:
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Skill pts: 0

About

I’m Sanjay Karthik, an Industrial Design Engineer doing business as ‘Dzign Forge’ with years of experience in Product Design & Development who's also passionate about transforming complex engineering problems into manufacturable and deployable technological solutions that meet the demands just right and also align with the latest engineering design standards.

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🏭 My Industrial presence includes, but not limited to;

🚗 - Automotive Industry
🛠️ - Special Purpose Machines
🌊 - Hydrodynamic Systems
⚙️ - Heavy Machinery Industry
⚡ - Power Generation Systems
🏗️ - Material Handling Systems
🚢 - Marine Engineering
✈️ - Aerospace Systems

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💼 Top-rated Industrial Expertise that delivers results to your business

📐 3D CAD Modelling & Design (CAD) Services:
🔹Conceptual 3D Modelling
🔹Engineering Parametric Modelling
🔹Product Rendering and Animation
🔹Sheet Metal Design & Fabrication Drawings
🔹Injection Mold Design and Manufacturing Drawings
🔹Composite Material Parts & Mold Design
🔹Casting & Machining Parts Design
🔹Reverse Engineering 3D Modelling
🔹Product Design for Manufacturing (DFM)
🔹Detailed Part & Assembly Modelling
🔹Rapid Prototype 3D Modelling
🔹Design Detailing for Product Visualization

🛠️ Computer-Aided Engineering (CAE) Services:
🔹Structural Design & Analysis
🔹Thermodynamic System Modelling
🔹Fatigue & Fracture Analysis
🔹Buckling & Stability Analysis
🔹Composite Material Analysis
🔹Micro & Nano-sized System Analysis
🔹Multiphysics Model Analysis
🔹Explicit Dynamic and Impact Analysis
🔹Modal Harmonic Analysis
🔹Linear & Non-linear physics study
🔹Static & Dynamic Analysis
🔹Noise, Vibration & Harshness Study
🔹Design Topology Optimization
🔹Virtual Product Testing
🔹Product Life Optimization study
🔹Design failure mode and effect analysis (DFMEA)

⚙️ Computer-Aided Manufacturing (CAM) Services:
🔹Sheet Metal Nesting Simulation & Optimization
🔹CNC Machining Operation Coding
🔹CAM Coding for 10+ Machining Operations
🔹Multi-axis Tool Path Creation & Optimization
🔹NC Programming for up to 5-axis Operations
🔹Sheet Metal Cold forming Die Design (Punching, Stamping, etc)
🔹Injection Mold Process Simulation & Optimization
🔹Composite Material Mold Flow Optimization
🔹Gear Cutting Operation NC Programming & Optimization
🔹Manufacturing Drawings & Technical Illustrations

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💎 What sets me apart as an Industrial Design Engineer

🔸Proven Track Record - Successfully completed over a dozen of well optimized & efficient projects.
🔸Ingenious Innovations - Catered unique & customized solutions within industrial adaptability.
🔸Creative Design Solutions - Fabricated exceptional designs by pushing beyond the limits of creativity.
🔸Design Certifications - Proficient in Multiple Design, Analysis and Manufacturing Softwares.
🔸Vast Industrial Exposure - Designed products tailored to different engineering domains and disciplines.

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🤝 Why choose to collaborate with me?

⭐ - Exceptional Quality - Delivering precise Engineering Solutions that exceed expectations.
🗣️ - Transparent Communication - Regular updates and follow-ups throughout the Project tenure.
💡 - Innovative Thinker - Catered Innovative Unique solutions to complex problems over the years.

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🚀 Let's Turn Your Vision Into Reality!

Ready to elevate your engineering projects with unparalleled computational power and expertise? Feel free to leave a message as I instantly respond to queries. I'm excited to collaborate and help you achieve your goals.

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📞 Get in Touch

Contact me today for a session to discuss your project needs.
Let's work together to make something phenomenal.

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Experience

  • Sr. Design Engineer Defense & Aerospace Industry · Full-time Dec 2022 – Dec 2024 2 yrs India Roles and Tasks undertaken as a Senior Design Engineer.

    - Structural and hydraulic Calculations as per IS 800 & ISO 3320.
    - Design and analysis of Loader Crane System Structure as per EN-12999 & IS 4573.
    - Hydraulic System Design, Integration & Testing as per IS 10585:2002.
    - FE Analysis of integrated systems - Static & Dynamic as per MIL 810.
    - System integration of sub-systems for HMV & Recovery Vehicles.

    Projects, Achievements & Key Highlights:

    Knuckle Boom Crane - Concept Design accepted for manufacturing to prove in-house capability.

    - 2.5% Structural weight reduction using Topology re-modelling in FE Analysis.
    - 1.2% Increase in Hydraulic cylinder efficiency by minimizing impact loads on lifting joints.
    - 1.5% Reduction in installation envelope by adjusting closed positions of Crane's arms.

    Awards & Appreciations:

    - Awarded for “Exceptional Performance in Design Optimization & Virtual Simulation”.
    - Received Appreciation from colleagues and Managing Directors for Off-domain contribution to Concept Design & development that led to the successful completion and closure of the project.
  • Design Engineer Stellantis · Full-time Jan 2022 – Jul 2022 6 mos India Roles & Tasks performed during Internship

    - Studied various procedures in Vehicle Design.
    - Design of Rear Cover Upper & Lower Cap - Ram Promaster vehicle.
    - Design of Rear Cover - Ram Promaster vehicle.
    - Design of Fuel filler cap - Jeep Compass Indian version.
    - Design of Front Fascia Bracket - Citroen SUV vehicle.
    - Design of Side Foot support bar - SUV vehicle.
    - Studied Procedures for Plastic Injection Molding including drafting, tooling, and mold creation.

    Achievements gained during the Employment period.

    - Completed 5+ courses on various procedures in Vehicle Design organized by the Company.
    - Designed Rear Cover Caps of Industrial van Tail Light - Reduced weight by close to 2%.
    - Front Fascia Bracket and Side Foot bar - Sped up modelling time by 15% using Design Optimization.
    - Practiced Injection flow simulation process. Reduced 0.5% material wastage in Partition Draft parts.
    - Studied Additional Procedures for Plastic Injection Molding including drafting, tooling, etc.
    - Completed a Design task within 2 weeks during the initial days of industrial training.

Education

  • Symbiosis International University Masters in Business Administration, Finance and Economics 2024 – 2026 (expected)
  • Symbiosis International University B.Tech, Mechanical Engineering 2018 – 2022

Other experience

  • Design for Manufacturing using Sheet Metal with Fusion 360 3D modelled a Drone Chassis 2mm sheet metal low strength sheet metal material. Coded an NC program for cutting sheet metal using a waterjet CNC machine. Performed load & CFD analysis based on the weight of components to analyze aerial performance and efficiency. Installed circuits and components for final assembly & concept rendering. Acquired certification & appreciation from fellow partners for Drone design.
  • Final Year Project - Research on Numerical simulation of heat transfer and pressure drop characteristics for non-Newtonian fluids in a microchannel Optimized a pre-designed microchannel to improve its performance and efficiency. Prepared a design with Calculations using a well-optimized geometry with increased thermal efficiency. Analyzed microchannel's performance using non-Newtonian fluid as a source using CFD simulations with ANSYS. Conducted virtual studies to understand its advantage as a replacement under various applications and optimized the solution. Compiled all research data into a research paper for publication under a certification Authority.

Licenses & Certifications

  • Manufacturing Process with Autodesk Fusion 360 Coursera Nov 2022 – Present See credential
  • Digital Manufacturing & Design Coursera Oct 2020 – Present See credential