SANJU NUKALA

Administer and maintain the company PDM/PLM engineering data environment, managing CAD models, product structures, revisions, and technical documentation to ensure full traceability across aircraft development programmes.

Manage configuration control and design baselines for aircraft assemblies including fuselage, wings, and tail structures, ensuring design definitions remain consistent across development and production.

Create and implement Engineering Change Notices (ECN) and Engineering Change Orders (ECO), ensuring all design updates are captured within the PLM system and communicated effectively across engineering and manufacturing teams.

Own and maintain Engineering Bills of Materials (E-BOM) for aircraft assemblies, ensuring alignment between design, production and supply chain.

Install, configure and maintain SolidWorks and engineering software environments for new engineers, including integration with PDM workflows and user access management.

Provide training and technical support for engineers on CAD tools, PDM processes and engineering documentation standards to ensure consistent adoption of configuration management practices.

Collaborate with design, manufacturing, operations and quality teams to develop and implement engineering policies, configuration procedures and design governance frameworks.

Maintain configuration status accounting records, tracking product revisions, released baselines and engineering change history across aircraft programmes.

Produce detailed 3D CAD models and manufacturing drawings while maintaining configuration integrity within the PDM system.

Coordinate engineering issue resolution across teams using Jira workflows, ensuring timely resolution of design and production issues.

• Designed and developed a robotic inspection platform for overhead line damage detection, including mechanical architecture, wheel systems, and structural components.
• Delivered DFM/DFA-compliant designs, ensuring manufacturability while maintaining performance and reliability targets.
• Managed product development documentation, including design reports, validation plans, and test documentation.
• Supported system integration activities, including motor selection, battery systems, and control architecture.

• Managed APQP and PPAP documentation, ensuring compliance with AS9100 and customer quality standards.
• Supported manufacturing readiness and product launches, ensuring supplier processes met quality, cost, and delivery requirements.
• Participated in MRB meetings, tracking non-conformance actions, and coordinating supplier corrective actions.
• Developed Process Work Instructions (PWI) to support manufacturing operations and improve production efficiency.

• Efficiently Operated and set up 2/3-axis CNC machines, conducted basic Troubleshooting, and ensured production quality through routine inspections.
• Performed Heat treatment, Rolling, and Bending of parts while maintaining records to comply with AS9100 standards.
• Collaborated effectively with the team, maintaining high inspection standards and continuously seeking improvement opportunities in line with AS9100 compliance.

• Designed and prototyped an e-bike powertrain, improving efficiency by 20% and reducing costs by 15%.
• Developed a high-capacity lithium-ion battery pack, reducing weight by 25% while increasing battery life by 30%.
• Integrated controller system with regenerative braking, extending runtime by 20 minutes.
• Delivered alpha and beta prototypes, testing subsystems and optimising performance.
• Conducted regular training sessions for boosting team's CAD proficiency.