Shraddhesh Subhash Kamal

Portfolio

A selection of my product design, mechanical engineering and data analytics projects.
For viewing a collection of my continuous improvement projects, please refer to the 'Experience' section on my LinkedIn page.

Apple Watch Series 8, 45mm

Decided to revive and improve upon a project that I originally started working on last year

Created a multi-body 3D CAD modeled part on SolidWorks using product dimensions for watch band lug-latch assembly and watch body available on Apple’s Official Accessory Design Guidelines

Used features like swept cut, circular pattern, etc. and surface modeling tools like thicken, thickened cut, etc

Converted the multi-body part into an assembly with multiple parts using Save Bodies command

Performed a motion study and created a pre-rendering mockup for final design/advertisement UI

Coming up soon:

Mechanical Drawings with BOM and GD&T

FEA for entire watch assembly

FEA for the watch bands to determine stresses created due to lateral slide-out force and pull force

Drop test simulation for watch assembly

Rendering using SolidWorks Visualize or KeyShot

STL Files for you to create your own watch bands and accessories!

Link to the Official Accessory Design Guidelines for Apple Devices
Disclaimer: The Apple Watch Series 8 logo and name are trademarks of Apple Inc., registered in the U.S. and other countries. This project is a personal, non-commercial representation and is not affiliated with, endorsed by, or approved by Apple Inc. Credits to the original creator/owner. No copyright infringement intended.

Apple Watch Band with Holes STL File
Apple Watch Band with loop and pin STL File

Used Car Decision Dashboard

Objective:

As a new graduate in Texas moving away from the university campus, I needed a reliable source of personal transportation. I started looking for used cars on the internet, but the vast number of options were confusing and somewhat overwhelming. Everyone wants the best deal in terms of cost and reliability. The objective of this project was to adopt a data-driven approach to determine which of the most common car brands that I see on the roads would be a reliable choice.

Achievement:

Developed Tableau dashboard utilizing NHTSA dataset of 235461 rows of entries for 19 car brands manufactured post-2009, aiding used car reliability assessment
Implemented filters for granular analysis by state and issue type, enhancing user insights
Monitored KPIs including total complaints per brand and issue distribution, facilitating informed decisions
Achieved a 99.69% reduction in manual data analysis time and improved decision-making efficiency
Mitigated risks by identifying potential issues early, preventing costly future servicing and maintenance charges, thereby improving ROI (Return-On-Investment)
Bought my first car!

LMNS (pronounced "Lemons")

LMNS is a continuously improving personal project which highlights my conceptualization, reverse engineering and advanced surface modeling skills. It helped me work on my NPI (New Product Introduction) understanding.

When life gives you lemons, download an STL file for a lemon juicer and 3D print it, reverse engineer the design to change the feature according to your preference, perform FEA, collaborate with vendors for DFM reviews, create a mold for injection molding, run a manufacturing simulation, create a physical prototype of the juicer via injection molding, create DVP&R and perform rapid iterative prototyping of the mold and the juicer, perform tolerance analysis and create drawings of the final model with BOM and GD&T for manufacturing, conduct physical testing of the model, while sipping on the lemonade that you made for yourself, conduct market analysis for gauging supply vs demand, start batch production of the final model, create such a brand identity that whenever life gives someone lemons, YOUR lemon juicer is the one they think of and buy!

Link to the Original Model that I improved upon: https://www.thingiverse.com/thing:1058165 (All credits to the original creator. No copyright infringement intended.)

STL File

Soft Robotic Jaw Force Sensor for Medical Applications

Conceptualized and modeled a novel, low-cost, human-centered design of a piezo sensor assembly to detect early onset of TMJ disorder

Conducted a non-linear, time-dependent structural analysis of the hyperelastic EcoFlex 00-10 sensor assembly using Ansys Workbench

Used SolidWorks for DFAM of silicone elastomer casting mold, followed by testing and calibration of prototype using Arduino IDE

Jaw Force Sensor Demo Video
Jaw Force Sensor Presentation
Final Report

Thermal Management of Electronics and Data Centers

Reviewed conventional technologies for cooling of electronics such as heat exchangers, heat sinks and thermal interface materials

Explained the use of functional materials in advanced cooling technologies such as heat pipes, vapor chambers and thermosiphons

Reviewed data center cooling processes and HVAC guidelines for room temperature and relative humidity as per ASHRAE TC 9.9

Thermal Management of Electronics and Data Centers Presentation
Final Report

Wearable Inertial Measurement Unit (IMU) Shoe for Gait Analysis

Invented and designed an ergonomic, dynamic foot gripping assembly to solve shoelace accessibility problems for people with disabilities

Performed an additive manufacturing simulation and a static structural analysis for the assembly using Ansys Workbench

Led a team of 4 to prototype a high-quality shoe with an IMU housing, modeled with parametric design curves using SolidWorks; created a scalable solution using New Product Introduction (NPI) process to accommodate different foot shapes and sizes

Presentation
Final Report
Assembly Demo Video

Mechanical Behavior of Fiber Reinforced Composites

Designed a matrix and reinforcement assembly using SolidWorks to simulate the effect of using combinations of metals/ceramic/polymer/composite materials with different elastic properties as both fiber and matrix

Modeled the elastic properties of Epoxy, eGlass, Aluminum, and Steel 355 using MATLAB

Performed an additive manufacturing simulation for the assembly using Ansys Workbench

Conducted a non-linear, time-dependent structural analysis of the additively manufactured assembly using Abaqus CAE

Mechanical Behavior of Fiber Reinforced Composites Presentation

On-site Repair Application of Additive Manufacturing

Modeled the properties of Structural Steel, Titanium Alloy, and Polyethylene on each of the 3 provided geometry variants (with defect, without defect, and repaired using additive manufacturing) of a bracket for pump application on Ansys Workbench

Conducted static structural analysis of the 3 variants of the bracket with adaptive sizing mesh, using Ansys Workbench

Conducted a transient thermal analysis for the repaired bracket via 'Element Birth and Death' technique using Ansys Workbench to perform an wire-arc additive manufacturing or DED (Directed Energy Deposition) simulation

Concluded on the best material and feasibility of additively manufactured repair for the specific pump application with the given loading conditions, on comparison of results for von Mises stress, deformation, normal stress and the factor of safety

Simulated the bracket for minor changes in the load magnitude for obtaining the optimum factor of safety value between 1 and 5, using the parametric simulation strategy

On-site Repair Application of Additive Manufacturing Report

Underwater Propulsion System Using Piezoelectric Actuator

Designed and prototyped a compact robotic fish with a solid-state piezo-fan as its tail for propulsion, using SolidWorks for modeling

Used COMSOL Multiphysics to simulate and analyze inverse piezoelectric effect, and Ansys Workbench and Fluent for CFD simulation

Fabricated the fish body with PLA, using FDM after additive manufacturing simulation on Ansys Workbench

Performed an IPX7 waterproofing test using commercially available silicone sealant

Piezo Fish Presentation

Power Optimization for a Wind Turbine

Formulated an initial optimization problem based on a simplified version of Blade Element Momentum Theory and certain assumptions for axial induction factor, drag coefficient, etc.

Used MATLAB’s Optimization Toolbox to solve the multi-objective function with constraints for a corrected model

Achieved an optimal value of power coefficient dependent on twist angle and chord length using Pareto Analysis

Final Report

Production Planning, Control and Management in Flexible Manufacturing Systems (FMS)

Reviewed the Manufacturing Planning and Control Systems (MPCS) Decision Hierarchy and explained its various levels

Explained the advancements in control systems for scheduling and material handling in an FMS

Studied the management practices of a card manufacturing company that implemented an FMS to determine productivity

Drafted a comprehensive report on all the findings

Final Report

Design and Analysis of Gun Recoil Control System for an Unmanned Aerial Vehicle

Implemented and optimized high precision motion control algorithms for drone stability using Arduino; enhanced target accuracy by 24%

Drafted mechanical drawings with GD&T ASME Y14.5, BOM and tolerance analysis, and defined project timelines using Gantt Charts

Drafted DFMEA, Designed for Manufacturability, and analyzed components using SolidWorks and ANSYS Workbench

Worked with PLA to model and prototype a drone which reduced weight and increased biodegradability as compared to ABS

Performed FEA Analysis of the drone’s arms and achieved a maximum deflection of 0.15 mm for a load of 2.6kN

Secured 4th position at the college project exhibition, INNOVEX

Poster Presentation

Design and Manufacturing of a Go Kart

Worked cross functionally in a team of 25 for fabrication of the chassis for the go-kart

Designed and analyzed components using SolidWorks and ANSYS Workbench for assembly and manufacturing

Manufactured components using applicable processes including traditional lathe machine as well as CNC machining

Reduced cost incurred in material change by retrofitting existing production process to accept new material

Negotiated with local vendors to procure high strength and low weight materials at the lowest cost based on market value comparison with 100% execution within budget

Design and Manufacturing of Student Formula Race Car

Managed a team of 30 and worked cross functionally as Team Leader & Chief designer of Transmission and Suspension system.

Drafted DFMEA, DVP, mechanical drawings with GD&T (ASME Y14.5), and BOM

Designed and analyzed components using SolidWorks, ANSYS Workbench and Lotus Shark for assembly and manufacturing

Designed and fabricated nose cone and body trim using fiberglass-epoxy resin composite; reduced part weight by 44%

Used rubber-dipping technique on steering wheel using plastisol to increase grip, provide insulation and improve aesthetics

Fabricated ergonomic seat by bonding and stapling PU leather; padded with high density polyurethane foam to increase durability

Manufactured components using applicable processes including traditional lathe machine as well as CNC machining

Woodworking: Jewelry Box

Repurposed a scrap block of Walnut wood to create a pocket-sized sleek jewelry box without mechanical hinges

Used vertical band saw and scroll saw to precisely divide the block into two with equal dimensions

Used belt sander and orbital sander to plane and smoothen the surfaces without using a planer machine

Constructed a custom jig for the plunge base router to create identical recesses for storage in both wooden blocks

Constructed a custom fixture for the router to create identical grooves in the blocks to open the box

Used drill press to create inserts for neodymium magnets to close the box

Used wood staining and polyurethane coating techniques in succession to accentuate and preserve aesthetics

Created a durable hinge using a combination of card paper, fabric and wood glue

Made a friend very happy!

Design of Centrifugal Pump for Domestic Application

Designed the suction and delivery pipes for actual discharge of 50 meters3/hour with a manometric head of 50 meters

Calculated the motor power and based on the results selected the most economic pump from supplier catalogue

Designed and analyzed components using SolidWorks and ANSYS Workbench for the results obtained from the calculations