Dev Kanani
Southampton
Summary
High-Performing Design Engineer with over seven years of experience in delivering production-ready components and assemblies in aerospace, railways, automotive and energy sectors. Owned full NPD (New Product Development) lifecycle from feasibility requirements, concept to detailed drawings, hands-on prototyping and test validation. Advanced CAD (SolidWorks, Creo) and CAE (ANSYS FEA, CFD) to optimise weight, cost and reliability. Proven track for accomplishing key product development stage by providing impactful design solutions to propose comprehensive modification techniques. Lead design reviews and drive on-time delivery across multidisciplinary teams for product development while balancing change control, risk management, DFMEA, tolerance stacks, supplier release and compliance.
Overview
8
8
years of professional experience
Work History
Research Assistant
Creative Machines Lab
- Conducted multiple experiments to develop the optimal PCB design board for AD9280, enabling seamless synchronization with Red Pitaya and STM32 for a live transmission feed. The final design achieved theoretical speeds of up to 32MSPS data points, facilitating the successful and clear transmission of live data for successful 2D image rendering of sonogram.
Mechanical Design Engineer | Lead Product Engineer (Interim)
Bowman eTurbo Systems
05.2023 - 08.2025
- Led product development NPD from feasibility to PRR, enforcing DFMEA, design for quality standard checklists and PDM controlled releases, coordinating cross-functional reviews to de-risk launch, reducing high-severity risks (RPN) by 30% and achieving standards compliant test readiness for electromechanical assembly.
- Delivered thermal and structural validation using FEA and CFD across turbocharger & electronics components with cooling enclosures, achieving measured performance within ±10 C of predictions and ensuring EMC compliance with IP55 rated standards for CNC-Machined and injection-moulded components post assembly.
- Managed cross-functional collaboration across design teams in US & UK, test, manufacturing, and supply chain via structured design reviews and interface checkpoints, cutting late design changes by 40% and accelerating milestone approvals from stakeholder sign-off through clear risk and verification evidence.
- Directed the Critical Design Review phase of an MNC client, converting a 400+ line function design specification (FDS) into a compliant standards matrix, while building and managing L1–L3 schedules to deliver parallel workstreams on time, securing stakeholder sign-off, avoiding rework, and authoring a post-NPD patent landscape that safeguarded IP and inform future product strategy.
Senior Design and Manufacture Engineer
Patel Industries Pvt. Ltd.
04.2022 - 01.2023
- Directed the design and assembly of an 11-spindle granite edge-polishing system of 1.1KW 2850rpm electric motors for cohesive multi-axial manoeuvres, while leading a team of 5 engineers to deliver customer installation on time and within budget.
- Validated coolant and containment flow using CFD (ANSYS Fluent), optimising enclosure seals and IP protection for moving axes, mitigating ingress risk and extending motor/electronics lifespan.
- Programmed and integrated motion control, I/O, for electrical and pneumatic controls and safety interlocks on the automated slab-cutting system using Allen Bradley PLC (WPLSoft-Ladder) and Kinco HMI, cutting setup time by 50% and improving operator safety compliance.
- Engineered and commissioned a high-speed barrel die-punch system for whistle candy moulding, achieving ~100 rpm throughput with a 0.5 s/piece cycle time, delivering production volumes of 5K units/hour.
- Optimised the syrup-to-straw joining station via nTop driven guides, seals, and fixturing in a continuous improvement sprint, cutting defects to 0.2% to 0.05% per hour and boosting first-pass yield by 50 units.
CAD Design Engineer
Ferry Machine
01.2021 - 04.2022
- Optimised 5-axis CNC changeovers, redesigning fixtures into modular plates with hardened locators and standardising offsets, tool libraries; cutting setup time by ~30% and boosting OEE and throughput during frequent SKU swaps.
- Designed and Standardised SolidWorks model-based definitions, configurations, and drawing templates, unblocking the design-to-sample pipeline and ramping up end-to-end workflows (BOM, routings, setup sheets, ECNs), eliminating line stops.
- Delivered Design for Manufacturing (DfM) framework on team designed parts and assemblies, resolving manufacturability issues early and preventing rework that would have added 15% to project costs.
- Conducted advanced testing and analysis of engine assembly components, resolving design challenges that reduced defect related warranty claims by 10% and boosted client satisfaction ratings by 5 base points.
Researcher
Dr. Sahin Laboratory – Extreme Biophysics, Columbia University
05.2019 - 12.2020
- Engineered a 0.85 cubic meter unit that generates 1.26W of electrical power from the humidity differential, utilising the hydration and dehydration cycle of cellophane’s compression properties to generate mechanical rotatory motion, demonstrating proof-of-concept for renewable energy systems in SolidWorks and Simulink.
- Investigated rotary evaporation engines, building model in SolidWorks and printing SLA/SLS parts; collected performance data to de-risk deployment and solution integration, delivering 50.23 mN
- M torque on a 10-wheel assembly for Additive manufacturing.
- Developed cost-efficient structure fabricated from Delrin and Acrylic, modelled in Altair (for FEA), by precise CNC milling and Laser cutting for the final product testing that gave ~1 W of power generation from evaporation.
Junior Engineer - Power System Engineer
Fairbanks Morse engine, Enpro Industries
05.2017 - 08.2018
- Documentation of quality control standards for Engineering Drawings, Bill of Materials, and CAD-based bench line inclusions across the factory as part of the new documentation adaptability process.
- Collaboration with quality engineers monitoring ISO aligned compliance on post-assembly engine performance, maintaining adherence to engineering safety standards through audits and corrective actions.
- Applied statistical time–motion mapping (industrial-engineering study) at the crankshaft installation station; advocated and implemented process changes that reduced install time by 40 seconds per engine.
- Contributed to development of a diesel-powered engine chassis, achieving reduction of 5% fuel consumption through design optimisation of motion control parts in Siemens NX.
Education
Master of Science - Mechanical Engineering
Columbia University
Bachelor of Science - Mechanical Engineering, Robotics & Thermal Systems
Bachelor of Science - Physics, Mathematics
Beloit College
Skills
- CAD Proficiency: Solidworks, CREO, Siemens NX, CATIA V5, AutoCAD, Fusion360, nTopology
- FEA, CFD, CAE Simulations: ANSYS Mechanical, Maxwell, MotorCAD, Fluent, Autodesk Inventor, Abaqus
- Product Management: Altium PCB design, Altair Inspire, MATLAB, Simulink
- Windchill PLM, Teamcenter PDM, ERP Epicor, Solidworks PDM control
- FE (EIT) certification and member of ASME (USA); ABET accredited institute; IEng UK Equivalent
- GD&T (ASME Y145/ISO 1101 standards), BS 8888, Tolerance stack-ups, ISO 9001, P&IDs, CAD and MRP BOMs, system interfaces, Technical drawings sign-offs, surface finishes
- Compliance & Standards: UKCA/CE, REACH/RoHS, UL/TUV certifications, EMC/IEMI compliance, H&S, Requirements (FDS) and compliance matrix
- Precision Mechanism Design: Designing complex linkages, gear train, Structural frames, welded assemblies, bearings and seals, balancing comms, RPN on design
- Systems engineering: V&V testing, ECR/ECN, RCA, 8D/5W, Lean Six Sigma principles, SOP docs, acceptance criteria, RSD tracing
- Materials & Manufacturing: Metal Alloys, Carbon composites, Additive Printing, Injection moulding, CNC sheet metal, jigs and fixtures, duty cycle time reduction
- Thermal & Fluids: Heat transfer & cooling system design, pressure-drop, hydraulic & pneumatic mechanism
- Analytical Calculations: simulation correlation, stiffness, fatigue, correlation to test, sensitivity, mesh convergence
- Robotics design: kinematics, actuators, motion planning, and machine vision integration, Sensor integration, PLCs
Websites
Timeline
Mechanical Design Engineer | Lead Product Engineer (Interim)
Bowman eTurbo Systems
05.2023 - 08.2025
Senior Design and Manufacture Engineer
Patel Industries Pvt. Ltd.
04.2022 - 01.2023
CAD Design Engineer
Ferry Machine
01.2021 - 04.2022
Researcher
Dr. Sahin Laboratory – Extreme Biophysics, Columbia University
05.2019 - 12.2020
Junior Engineer - Power System Engineer
Fairbanks Morse engine, Enpro Industries
05.2017 - 08.2018
Research Assistant
Creative Machines Lab
Bachelor of Science - Mechanical Engineering, Robotics & Thermal Systems
Bachelor of Science - Physics, Mathematics
Beloit College
Master of Science - Mechanical Engineering
Columbia University
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