2022 —
Lead Design Engineer
ACHALA IT SOLUTIONS
Hyderabad, India
2019 — 2021
Co-Founder & Principal Design Engineer
MIGHTYSEED DESIGNS
Coimbatore, India
2018 — 2019
Consultant
CAPGEMINI
Pune, India
2017 — 2018
Design Engineer
TICKET DESIGN
Pune, India
2014 — 2017
Project Lead
QAUTOMATION
Coimbatore, India
My Experience
Adithyan G is a Mechanical Design Engineer with a decade of experience in the medical device and consumer product design industry. He is proficient in industry-standard software, including SolidWorks, Fusion 360, and Keyshot. His technical expertise is validated by certifications such as CSWP, GD&T ASME Y14.5 2009, and SolidWorks Simulation Professional.
Adithyan has a strong foundation in 3D CAD, DFX, and Simulation, enabling efficient transformation of industrial design concepts into manufacturable products. He is skilled in designing components for various manufacturing processes, including injection molding, sheet metal fabrication, and precision machining. His portfolio includes experience in mentoring design interns through the design process.
As a Co-Founder and Principal Design Engineer at Mightyseed Designs, Adithyan collaborated with over 13 clients, showcasing his proficiency in customer engagement, requirement analysis, and project management. He leads end-to-end product engineering, from concept to production, optimizing designs for cost reduction and assembly efficiency. His commitment to quality is evident in his development and implementation of a Design Engineering Methodology based on DFSS principles.
To stay at the forefront of industry advancements, Adithyan recently completed the Executive Programme in Healthcare for Industry 5.0 from IIT Delhi. This program equipped him with insights into integrating human centered design, focusing on personalized and sustainable healthcare solutions.
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1/5
Challenge
The highly sensitive sensors used for measuring liquid drops, required precise quantity of light exposure and high transmission of light through sensing window, while keeping the IP 54 rating of the device intact.
Solution
PMMA(Acrylic) material, which has a light transmission ability of 92% (only next to glass which has 100%) was used as the material for sensor window, and the injection molding was done in two stages, following the concept of insert molding to control gaps and achieve IP 54 requirements.
Dripo
Medical Device
DFM
Material
2/5
Challenge
A compact portable device that needs to be carried by a patient, needs to have multiple functional elements inside the body and flexible elements such as electric wires and pneumatic tubes, has to be planned and organized in advance, while designing for ease of assembly.
Solution
The Pneumatic tubes and Electric cables were designed in CAD using routing options, the design had considered the minimum bending radius of the tubes and cables, as different wall thickness tubes will have different bending readius.
Wound Therapy
Medical Device
DFA
Routing
4/5
Challenge
During the fatigue test, the plastic pocket, housing the pivot pin, which is a critical component in the tacker, was found to fail before completing the minimum required number of lifetime cycles.
Solution
During the fatigue test, the plastic pocket, housing the pivot pin, which is a critical component in the tacker, was found to fail before completing the minimum required number of lifetime cycles.
Tacker
Consumer Products
FEA / Simulation
3/5
Challenge
After the pilot production of the device, a drop test was conducted and the Hook at the bottom of the device provided for supporting the tube was found to fail, with the projected plastic separating from main body.
Solution
Drop Test study on the body was conducted to analyze the failure reasons, based on results the design was modified with additional ribs and materials with high impact resistance properties were chosen and the tool was modified accordingly. the final product then passed the drop test.
Dripo
Medical Device
FEA
Material
5/5
Challenge
Fixtures used for mounting and assembly of large machinery and control panels that can weigh up to a few tons require careful material choice and CAE validation, as any failure can cause considerable damage and injuries.
Solution
Structural Simulation along with real boundary conditions such as gravity are included and to save the simulation time, complex parts are simplified without affecting the center of mass of the entire assembly.
Fixture
Transportation Industry
FEA/Simulation
Short Case Studies
Dripo
Infusion Monitoring Device with IP 54 ratings
Biocalculus
Heart Rate Monitoring Device with IP68 ratings
Modular Lunch Box
Industrial Design Concept
Digital X-Ray
Reverse Engineering Project
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Display Panel
Industrial Design Concept
Bike Concept
Secured 7th place in GrabCad Global Challenge in collaboration with Solidedge and Keyshot
Automation SPMs
Special Purpose machines with Sheetmetal Body
Portfolio
Ideate. Create. Deliver.
2022 —
Lead Design Engineer
ACHALA IT SOLUTIONS
Hyderabad, India
2019 — 2021
Co-Founder & Principal Design Engineer
MIGHTYSEED DESIGNS
Coimbatore, India
2019 — 2019
Consultant
CAPGEMINI
Pune, India
2017 — 2018
Design Engineer
TICKET DESIGN
Pune, India
2014 — 2017
Project Lead
QAUTOMATION
Coimbatore, India
My Experience
I have been working with Achala IT Solutions since 2022. I have been involved in a number of different projects, from designing and engineering Heathcare devices .
As a Lead Design Engineer, I am an expert in 3D modeling and have extensive knowledge of materials and manufacturing processes. My extensive experience in the field has equipped me with the skills to create innovative designs that are not only aesthetically appealing but also functional and cost-effective.
In addition to my core responsibilities of working firsthand developing products for manufacturing, I also manage a team of designers, ensuring that projects are completed on time and to the highest standard. With my strong leadership skills, I am able to motivate and guide my team to achieve their full potential, contributing to the success of the company.
1/5
Challenge
The highly sensitive sensors used for measuring liquid drops required precise quantity of light exposure and high transmission of light through sensing window while keeping the products ip 54 rating of the device intact.
Solution
PMMA(Acrylic) material, which has a light transmission ability of 92% (only next to glass which has 100%) was used as the material for sensor window, and the injection molding was done in two stages, following the concept of insert molding to control gaps and achieve IP 54 requirements.
Dripo
Medical Device
DFM
Material
1/5
Challenge
After the pilot production of the device, a drop test was conducted and the Hook at the bottom of the device provided for holding the tube was found to fail with the projected plastic separating from main body.
Solution
Drop Test study on the body was conducted to analyze the failure reasons, based on results the design was modified with additional ribs and materials with high impact resistance properties were chosen and the tool was modified accordingly. the final product then passed the drop test.
Dripo
Medical Device
FEA / Simulaion
Material
1/5
Challenge
During the fatigue test, the plastic pocket, housing the pivot pin, which is a critical component in the tacker, was found to fail before completing the minimum required number of lifetime cycles.
Solution
With the help of simulation, required amount of plastic thickness needed to be added to the plastic housing to make the product withstand for longer cycles was determined, the modification was done on the tool and the solution had proven to work.
Tacker
Consumer Products
FEA / Simulation
Short Case Studies
Software Expertise
Solidworks
Keyshot
Photoshop
Editor X
Figma
Notion
Fusion 360
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Microsoft 365
Portfolio
