Hitesh Raj
Aravind
Mechanical & Automotive Systems Design Engineer
I design, analyse, and validate mechanical systems using CAD, FEA, and CFD. From automotive components at Bosch and Essae, to industrial machinery at Koolmill Systems, to academic research at the University of Hertfordshire. I build things that work.
Built on first
principles
Mechanical & CAE
Engineer
I build mechanical systems that hold up under real load, not just on paper. With an MSc in Automotive Engineering and hands-on experience across industrial machinery, motorsport aerodynamics, and structural analysis. I use simulation and CAD to make engineering decisions that are fast, validated, and manufacturable.
Most recently at Koolmill Systems, I took a precision rice milling platform from concept to prototype by running FEA, managing tolerances, writing supplier documentation, and presenting to the CTO. Before that, Formula 1 front wings, electric vehicle chassis, and materials research at the University of Hertfordshire.
I have worked across India and the UK. I operate at the intersection of design and analysis where decisions get made with data, not assumptions.
Design &
Engineering work
Electric Tricycle Platform
Full design development study from concept to validated CAD & FEA in CATIA V5, mesh independency study, material optimisation, and multi-run structural analysis.
- Chassis modelled in CATIA V5 to support 3 people under 4500 N combined load
- Al 6061 selected over Mild Steel and CFRP for optimal weight, cost, and strength
- FEA optimisation reduced displacement by 20% and principal stress by 30%
- Frame designed to carry up to 450 kg; Al 6061 assembly kept under 30 kg total weight
- Fillets of 15 mm and 30 mm radius applied iteratively to redistribute stress concentration points
F1 Front Wing CFD
Aerodynamic CFD analysis of an F1 front wing at 259.5 mph using STAR-CCM+. Mesh independency study across 7 base sizes with full flow visualisation.
- Simulated drag and downforce at race speed; 0.5 m mesh selected as optimal
- Streamline analysis identified vortex formation behind the nose cone
- Kappa-Omega turbulence model applied for realistic boundary layer behaviour
- Symmetry plane used to halve computational domain; results mirrored for full wing analysis
- Pressure and velocity streamlines revealed high-stress region under nose requiring canard redesign
Redbull F1 Wing FEA
Structural FEA and modal frequency analysis of a Redbull F1 front wing under 2415 N/m² aerodynamic load. 8 materials evaluated.
- 3.5 mm mesh / 0.35 mm sag identified as optimal through independency study
- Spectra 1000 selected: lowest displacement at 5.75 mm, weight 12.12 kg
- Frequency analysis conducted across 10 modes for all 8 materials
- Bulkhead clamped to simulate mounting conditions; downforce load of 2415 N/m² applied to wing surfaces
- Zylon HM showed lowest displacement but exceeded target weight; Spectra 1000 selected as optimal balance
Sn-Cu Alloy Investigation
Materials engineering investigation into how casting mould affects mechanical properties of Sn-0.7wt.%Cu solder alloy across four distinct cooling systems.
- Copper cooling produced highest UTS at 20 MPa; furnace cooling lowest at 15 MPa
- SEM and SEM-EDX used to analyse microstructural grain formation and IMC distribution
- Faster cooling rate produced finer β-Sn grain sizes and Cu₆Sn₅ IMC structure
- Water-cooled system (1.66 °C/s) yielded highest tensile strength; mould-cooled (0.04 °C/s) gave highest elongation
- XRD and SEM-EDX mapping confirmed two-phase Sn-rich and Cu₆Sn₅ intermetallic distribution across all specimens
Professional
history
Jun 2025
- Designed and optimised mechanical sub-systems for the MBS-F1 precision rice milling platform from concept to prototype validation
- Led modular sub-system development applying DFMA and DFM principles for global deployment configurations
- Conducted FEA simulations (Inventor, ANSYS Workbench) for stress, thermal behaviour, and fatigue life by enabling 15% improvement in structural reliability
- Delivered manufacturing-ready designs with full GD&T, tolerance stack-up, BOMs and supplier documentation aligned to BS 8888 and ISO 2768
- Spearheaded RCA and DFMEA for product failures during field trials, reducing downtime and iteration cycles
- Supported engineering change control with sourcing, manufacturing, and compliance teams (CE/UKCA)
- Presented data-backed design proposals to senior leadership including the CTO during formal design reviews
- Developed assembly documentation and QA checklists for production partner build and inspection
Jul 2024
- Delivered applied mechanical engineering instruction aligned with BTEC curriculum which included design fundamentals, thermodynamics, fluid mechanics
- Designed CAD-based demonstrations and lab exercises connecting theory to real-world mechanical systems
- Prepared structured learning material and supported student problem-solving and technical reasoning
Nov 2023
- Worked part-time after completing MSc studies while actively seeking a full-time engineering role
- Operated within defined procedures and process standards in a fast-paced customer facing environment
Aug 2023
- Delivered structured engineering instruction at Bucksmore Education's Oxford centre in a high-responsibility academic environment
- Taught and mentored students from over 8 countries, adapting explanations to varied educational backgrounds
- Operated within strict safeguarding, quality, and compliance frameworks
Jul 2023
- Worked in a high-throughput, quality-driven fulfilment environment during MSc studies
- Maintained attention to detail and operational discipline under time pressure
Mar 2020
- Created automotive components (gears, wheel bearings, flanges, shafts) in CATIA V5 following OEM specs and ISO TS 16949 standards
- Identified process anomalies to improve machining efficiency
- Led cross-functional team in Root Cause Analysis using the 8D method to reduce design failure points
- Conducted Kaizen events enhancing productivity across 150+ employees
- Developed Bills of Materials and established ISO TS 16949 quality standards within the design department
Feb 2019
- Evaluated manual assembly stations for in-line diesel injection pumps aligned to ISO 13948-1:2015 standards
- Analysed daily production times to identify most efficient assembly design with minimal defects
- Collaborated with error handling specialists to reduce assembly time and improve production quality control
Certifications &
technical skills
Engineering certifications, simulation workflows, CAD systems, and product development methodologies.
0929 Labs
Experimental engineering and future systems studio focused on advanced concepts, technical experimentation, and next-generation product development. Currently in a controlled early development stage with exploration of the intersection between structural engineering, simulation, and emerging manufacturing methods.
Open to engineering opportunities
Available for mechanical engineering, CAE, simulation engineering, product development and automotive engineering roles in India and internationally.
📍 Bengaluru, India · Available for global remote & relocation opportunities