Ketan Nehete

Design, Prototype, Test, and Validate new mechanisms for the future versions of the Stretch robot.

Capstone Project @ UC Berkeley: ● Designed an active exoskeleton with a single actuator, driven to target a 60–70% reduction in muscle strain for warehouse workers, optimizing motion control algorithms to support repetitive overhead tasks while minimizing system weight. ● Accomplished universal user compatibility through biomechanically optimized adjustable frames and ergonomic interfaces, enabling customization for diverse body types without compromising mobility; achieved using adjustable push-button locks. ● Executed iterative design refinements across three major exoskeleton prototypes, resolving critical issues such as joint instability and arm bar fractures, achieving failure-free operation under load testing while maintaining 85% of the target range of motion

- Developed "Stoch4," a quadruped robot, including actuator design (1:6 planetary gearset), torque/force analysis, motion control, and custom body design with optimized weight and strength. - Manufactured actuators using EN8 gears (wire-cut and hardened) and managed vendor sourcing, procurement, and quality assurance. - Cast polyurethane foot padding in-house, testing hardness levels for optimal grip. - Integrated electronics (computers, cameras) into the robot’s enclosure with efficient cable harnessing and custom strain relief components. - Designed battery casing with Battery Management System (BMS), balancing weight constraints and strength. - Used SolidWorks for CAD modeling and ANSYS/Nastran for FEA and topology optimization. - Redesigned shank using generative design, reducing weight by 15% and increasing strength by 22%, manufactured via metal 3D printing. - Designed actuator heatsinks to extend operational uptime by 30 minutes. - Reduced maintenance time by over 40 minutes through improved assembly design. - Created a Bill of Materials (BOM) for cost-efficient manufacturing under $1000 per robot. - Built URDF models and integrated them into ROS; tuned controllers for gravity compensation, standing, sitting, walking, and pose estimation. - Contributed to "MULE," a high-payload quadruped robot (25 kg capacity), optimizing shank geometry and designing a robust torso for electronics with airflow management and dynamic load resistance. - Enhanced MULE 2.0 with stronger torso designs, chain-driven thigh links with inline tensioners, and foot contact sensing for better control. - Designed mechanical couplings for secure motion transmission while reducing assembly time. - Worked extensively with rapid prototyping (3D printing) to validate designs and collaborated with manufacturers to produce components per GD&T standards.

- Mechanical Design & Optimization: Engineered lightweight, ergonomic outer casing for Stoch-Lite; optimized shank design achieving 1.5x strength increase without additional weight (validated via ANSYS structural analysis). - Product Development & Manufacturing: Designed and manufactured multiple iterations of foot padding molds, significantly reducing overall volume; executed in-house polyurethane casting processes. - Vendor Management & Procurement: Collaborated with specialized vendors for precision manufacturing (Laser Cutting, CNC Machining, 3D Printing, Metal Additive Manufacturing) of critical components such as heat sinks and actuator mounts. - Robotics Assembly & Sensor Integration: Led assembly and integration of mechanical components into Stoch-3 robot; developed and tested integrated foot-contact sensor setups to enhance robot sensing capabilities. - Actuator Design & Development: Designed compact actuators tailored for Stoch-Mini applications; performed component selection (bearings, encoders) to optimize actuator performance and reliability. - Sensor Technology & Feedback Systems: Developed a hall-effect-based encoder system enabling accurate leg position feedback post power cycling, significantly improving robot reliability and operational efficiency. - Robotics Software & ROS Implementation: Authored and maintained URDF files for precise robot modeling; gained extensive hands-on experience in C++ programming within ROS framework, enhancing software functionality for Stoch-3.

- Designed competitive robotic mechanisms in Autodesk Fusion 360 aligned with Robocon 2020 competition specifications - Fabricated functional prototypes using aluminum extrusions, CNC machinery, and additive manufacturing (3D printing) technologies - Conducted structural analysis using ANSYS simulation software to optimize component performance and durability - Collaborated in interdisciplinary team to solve complex robotics challenges through mechanical, electrical, and software integration - Engineered competition-ready prototypes for Robocon 2019, 2020, 2021 and 2022 themes implementation using mechanical power transmission systems - Gained hands-on experience in full product lifecycle from CAD design to physical assembly and testing

- Executed CAD modeling and technical drafting for industrial valve assemblies using SolidWorks software - Prepared production-ready engineering drawings with GD&T compliance - Optimized existing CAD models for manufacturing feasibility and assembly sequence validation - Developed comprehensive design documentation packages including BOMs and component specifications - Applied parametric modeling techniques to enhance existing product documentation systems - Conducted design reviews to verify dimensional accuracy against technical schematics

- Spearheaded a team to develop a voice-controlled robotic hand with IoT-enabled remote operation using Google Assistant/IFTTT integration - Designed biomimetic 3D-printed mechanics in Fusion 360 and programmed ESP32 microcontroller (Arduino IDE) for 5-DoF finger articulation - Engineered Adafruit.io cloud architecture for real-time command processing (<1s latency) and servo control via SG90 motors

Specialization: Control of Robotics and Autonomous Systems

An autonomous institute under Savitribai Phule Pune University.