Design Portfolio

Adwait Mahajan

About me

I am an Engineering Design graduate student looking for a summer internship as a design engineer in 2024.

I believe a great design is one that delivers form and function at the same time. Aesthetics of a product are as important as the function of the product. Additionally, the greatest products are formed when all the stakeholders such as customers, designers, engineers, manufacturers and corporations contribute together.

Education

Experience

Skills

Certifications

The Pennsylvania State University, USA

Masters in Engineering Design

(2023 - 2024)

Savitribai Phule Pune University, India

Bachelors in Mechanical Engineering

(2019 - 2023)

Knorr-Bremse Technology Centre India, Pune

Design Engineering Intern

Test Engineering Intern

Srivin Engineers, Pune

Mechanical Systems Intern

Resonance Racing India, Pune

Head of Chassis and Ergonomics Department

SolidWorks

Creo Parametric

Adobe Photoshop

Adobe Illustrator

Human-centred Design

Design Thinking

Product Lifecycle Management

Human Factors and Ergonomics

Additive Manufacturing

Prototype Development

Certified SOLIDWORKS Associate (CSWA)

Global Design Thinking Workshop (GDTW) - Strategic Futures

Product Design and Manufacturing

Design Thinking - A Primer

Quality Control in Manufacturing

Design, Technology and Innovation

Got lost reading the information?

WORK

01

Global Design Thinking Workshop

I participated in the The Global Design Thinking Workshop (GDTW) organized by the HPI d-school at Hasso Plattner Institute in Potsdam, Germany during March 7th to 13th 2024. It brought together 28 participants and 12 design coaches representing 18 diverse nationalities all united by a passion for innovation.

Sponsored by Cradle to Cradle NGO (C2C NGO), this year's theme was Strategic Futures - designing sustainable supermarkets of tomorrow. The five days of the workshop were of full of fun and learning and delved deep into problem scoping, observation, synthesis and ideation, prototyping and testing, and presentations.

Our team, 4-ward conceptualized and developed an interactive screen attached to shopping carts that displays individual sustainability scores for products, as well as a mobile application providing detailed information on CO2 emissions, water consumption, and packaging requirements. This system aims to empower consumers to make informed and sustainable choices while shopping.

02

DPM Master Block

As an mechanical design engineering intern and project lead at Knorr-Bremse, I was tasked with designing a solution to calibrate the hand brake valve test bench at one of their testing labs.

I executed the crucial steps involved in the Product Design process for angular calibration of Hand Brake Valve performance test bench while collaborating with multiple stakeholders like Design Engineers, Product Managers, Manufacturing Suppliers and Testing Engineer at Knorr-Bremse Technology Centre India Pvt Ltd.

The Problem

Multiple samples of hand brake valve are tested on the "Hand Brake Valve Performance Test Rig". However, test rig components such as the motor and angle encoder need to be calibrated twice a year for errorless testing.

Currently, master samples of the product are used to calibrate the test rig. But, the master samples are sent annually to its Hungarian facility for re-calibration which involves huge shipping and logistic costs, manpower costs and most importantly time.

The non-linear stages of design and development

Sketching

Multiple sketches were drawn on paper and the best one was selected after consulting all stakeholders.

Prototyping

Low fidelity prototype was created using cardboard to better visualize the ideas.

Manufacturing

The ideas were brought to life using conventional VMC manufacturing and lab testing.

After deeply understanding the problem, we started with design thinking and brainstormed a lot of ideas. The selected ones were modeled on SolidWorks.

After multiple iterations, individual components were designed and assembled. Engineering drawings were created and sent to a machined parts supplier for manufacturing.

Front Section View

Side Section

View

Manufactured

Parts & Assembly

CAD visualization on

test bench

03

SAE BAJA 2021

As a chassis design and ergonomics lead of Resonance Racing India, I carried out design, ergonomic assessment, prototyping and manufacturing of an all-wheel drive all-terrain vehicle.

Additionally, I maintained a continuous communication with the power-train, suspension, braking, data acquisition, manufacturing and driver teams to understand their needs and requirements.

Creation?

Ergonomics & Design

Chassis sub-systems

Pedals, Seat and Steering wheel were designed considering the ergonomic requirements of the driver.

Ergonomic factors such as driver positioning, driver movements, contact surface interaction, longer term physiological effects, ease of ingress and egress and driver's field of vision were taken into account while designing the chassis frame and sub-systems.

04

Fish Farming Made Easy

Hexarech

Hexarech is a fish farming social venture based in Kisumu, Kenya. Our mission is to develop innovative locally manufactured fish cages for fish farmers. Inspired by this initiative, I took on the challenge of designing a logo that captures the essence of Hexarech – a logo that not only reflects the aquaculture industry but also resonates with its core values.

Featuring a sleek fish with the name "HEXARECH" seamlessly integrated, the logo embodies our commitment to sustainable aquaculture. The choice of white and blue hues symbolizes Lake Victoria and our dedication to environmental responsibility.

EDSGN 100 MAKER SPACES

As engineering design graduate student, me and my team were tasked with identifying the current problems faced by undergraduate students at the maker spaces at the Engineering Design & Innovation Building at Penn State and provide viable solutions.

We started with a survey directed towards students, teaching assistants, instructors and cleaning helpers to understand their problems better and empathize with the users.

We redesigned glue gun and knife holders, work tables and safety glasses holders.

05

After much brainstorming and sketching, we came up with design ideas and made CAD models in Solidworks. To test our ideas and bring them to life, we 3D printed our designs using Prusa printers and gained feedback from the users.

The new safety glasses holder has holes underneath to prevent dust buildup and a sliding tray for easy cleaning. Glue gun holders now include knife holders for added safety. Worktables feature cutting and glue mats while side edges, and dust tunnels facilitate debris cleaning. Each table is labeled with a number for student ownership.

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