Precision mechanical design, from concept to production line.

Part of a medical supply drone project at the Kathmandu University Design Lab. I used generative design in Fusion 360 to optimise the airframe, then printed FDM prototypes to check fit and handling.

Weight-to-thrust calculations drove the selection of battery, motors, PCB and camera, so the airframe and payload were sized together.

Casting simulation of a 92 kW Francis turbine runner for the Turbine Testing Lab at Kathmandu University, covering thermal, solidification and shrinkage porosity behaviour in ProCAST.

The results were validated against photogrammetry of a 3D printed pattern and a lost-wax cast prototype, and published in AIP Conference Proceedings. This was my undergraduate thesis, which I continued in the Design Lab role.

A concept fridge that wheelchair users, their families and carers can all use comfortably, taken from storyboards and sketches through to rendered concepts and an IoT architecture built around a Raspberry Pi.

• Every shelf reachable without bending, with slide-out drawers and baskets
• Motorised door opener, easy-reach controls and handles
• Camera, motion, ultrasonic and button sensors for spoilage tracking, expiry reminders and remote access
• Sized for a family of two to five and to fit an existing fridge space

Using photogrammetry to improve the ergonomics of prosthetic limbs for below-knee amputees. A mesh generated from photographs of the residual limb was aligned with conceptual sketches in Fusion 360 to model a socket that was ready for 3D printing.

A generative design approach to product development, demonstrated on a guitar holder. The optimised form was printed as a mother pattern, used to make a silicone mould, then a wax pattern, and finally cast.

I published a paper on this approach.

A 3 m triangular lattice mast for field monitoring stations, designed and drawn at Real Time Solutions in 2020. The chords are 25.4 mm aluminium tube with a 1.65 mm wall, laced with 9.5 mm aluminium bar, and sections join by swaging one tube end into the next.

A concept layout for an automated insect-rearing sort line, sized to process one million samples per day. Trolleys of capsules feed tray and capsule conveyors, a 15-camera inspection array rejects empty capsules, and robot arms handle tray transfer and chimney and pot separation.

Sorted insects are routed by sex to the mating chamber or the radiation chamber, with trays cycled back to storage. The process flowchart defines each hand-off.

For Pro-mech Minds, I researched materials that could replace single-use plastic and metal containers in food delivery, then redesigned the container and lid around moulded bagasse with a 2.5 mm wall. The three-month project also covered the cost of setting up production.

Designed for the Kathmandu University Community Education Project, which puts engineering students to work on improving quality of life in rural communities.

The press forms three briquettes at once using an Acme lead screw and hydraulic jack on a welded steel frame, with a perforated base plate and male die to form the fuel holes.

A complete forklift modelled in Creo Parametric, from mind mapping and paper sketches to a full assembly.

• Parametric wheels and rims, shafts, chassis, fork, lifts, carriage, seat, steering, hydraulic cylinders and push rods
• Sub-assemblies for wheels and shafts, carriage and fork, and top frame, brought together in a final assembly
• Part drawings, exploded views, ballooned bill of materials

An injection moulding study of a tape dispenser used for wrapping goods and gifts. I simulated the part in Autodesk Moldflow to check fill time and shrinkage before committing to tooling.

A concept motorcycle modelled and rendered in Fusion 360.