Nitesh Kottai

SMART LIFT TROLLEY SPM: Led end-to-end mechanical design of a smart lift trolley for assisted installation of MEP components at construction sites —reducing site manhours by 50% through ergonomic load-assist mechanism design, structural frame optimisation, and DFM-compliant fabrication drawings. CEILING DRILLING SPM: Led end-to-end mechanical design of a ceiling drilling machine for automated drilling and mounting of threaded bolts for MEP hangers —reducing construction manhours by 60%; designed drilling axis, feed mechanism, and structural frame with SolidWorks; applied DFM and tolerance stack-up analysis throughout. Lead end-to-end mechanical design for bespoke industrial systems — developing 3D component models, structural assemblies, and GD&T-compliant 2D engineering drawings from concept through production handover. Design structural skids, brackets, and support structures for FAHU & VRV units — applying DFM principles, stress path analysis, and weight optimisation throughout. Perform tolerance stack-up analysis; define fit, clearance, and assembly procedures for precision mechanical assemblies. Coordinate with manufacturing teams to resolve machining, welding, and assembly deviations; support root cause analysis (RCA) for design-related production non-conformances. Maintain full engineering documentation suite — BOMs, revision control, change records — in compliance with ISO 9001 quality management procedures.

▸ NDT SPM — Missile Component Inspection Twin robots on independent linear gantries, a rotary table for vertical inspection, a roller mechanism for axial inspection, and a telescopic axis for inner surface inspection of the missile body. ▸ NDT SPM — Bomb Shell Inspection Immersion tank with roller mechanism for component holding; integrated 5-axis gantry system for coordinated ultrasonic probe movement across bomb shell geometry. ▸ NDT SPM — Spacecraft Fuel Tank Inspection Immersion tank with vertical rotary mechanism; 5-axis gantry for ultrasonic probe movement; additional roller mechanism for axial rotation of the fuel tank during scanning. ▸ NDT SPM — Railway Axle Inspection System Immersion tank with roller mechanism; 5-axis gantry system; cradle mechanism for axle handling; infeed/outfeed conveyor system; overhead handling gantry for axle placement between stations. Led mechanical design of all complex industrial SPMs for defence clients — responsible for shafts, couplings, structural frames, drive housings, and precision rotating assemblies using SolidWorks. Applied GD&T and tolerance stack-up analysis to rotating and dynamic component interfaces; generated complete drawing and documentation packages for global manufacturing partners. Conducted DFMEA/FMECA for safety-critical systems — identifying failure modes, criticality rankings, and design mitigations; supported operability and safety assessments per client requirements. Designed and specified sealing arrangements and precision clearance-critical interfaces for rotating assemblies; defined material selections across steels, cast components, and engineering alloys. Mentored and developed a team of 6 junior and mid-level engineers providing constructive feedback, establishing design standards, and improving first-pass drawing approval rates. Controlled full engineering documentation suite drawings, BOMs, manuals, test reports, change records per ISO 9001 frameworks.

▸ 10-Axis Dual Tower Squirter Inspection System Full end-to-end design and commissioning management for aerospace/defense component inspection with complex contour scanning requirements. ▸ NDT SPM — Railway Bearing Inspection Three conveyor systems for handling, a handling robot, two inspection tanks with an integrated rotary table, and a 5-axis gantry for ultrasonic probe movement. ▸ NDT SPM — 155mm Calibre Bomb Shell Inspection Three conveyor systems; handling robot; inspection tank with roller mechanism and 5-axis gantry system for complete ultrasonic inspection of shell geometry. Managed design execution for system upgrades, modifications, and obsolescence replacement for precision mechanical systems — resolving complex structural, tolerance, and manufacturing challenges. Performed DFMEA, ANSYS FEA validation, and tolerance stack-up analysis for safety-critical rotating and structural equipment; ensured compliance with applicable engineering standards. Reviewed manufacturing deviations from workshops; collaborated with production on DFM improvements and machining process optimisation. Contributed to root cause analysis (RCA) and corrective action activities for field failures — identified design improvements and fed lessons learned back into engineering standards. Provided technical inputs and design effort estimates for commercial proposals; supported business development across OEM accounts.

▸ NDT SPM — Battle Tank Gun Barrel Inspection Barrel handling axis in immersion tank; roller axis for component rotation; 6-axis gantry system for coordinated ultrasonic probe movement across gun barrel geometry. Produced detailed manufacturing drawings, assembly procedures, and BOMs for precision mechanical assemblies and industrial systems; managed drawing revisions and documentation control. Supervised prototype and pre-production build, pre-FAT testing, and quality inspection — validating assembly conformance to design intent, dimensional tolerances, and client specifications. Assisted instrumentation definition and measurement point identification for functional testing activities.

Developed component-level 3D models and 2D drawings; performed engineering calculations and supported senior engineers through detailed design phases. Gained hands-on experience in mechanical assembly, fitting, on-site commissioning, and basic structural analysis workflows.