Amitkumar J.
Lead Mechatronics & Mechanical Design Engineer @Bigsis Insect Control
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WORK HISTORY
Lead Mechatronics & Mechanical Design Engineer @Bigsis Insect Control
Module 1 Leader on a world-first AI-integrated automated insect production platform. BigSis was recognised as a Bloomberg UK Startup to Watch (2023) and a WIRED Trailblazer (2025), raised over £11 million in equity and UKRI grant funding, and held approximately 16 patent documents.• Led a cross-disciplinary team of four engineers covering mechanical design, electronics, firmware and AI to develop Module 1 — the central and most technically complex subsystem of the BigSis production line.• Took the full module from early-stage prototype through four development iterations (V1 to V4) to achieve a production throughput of one million insects per week.• Designed and integrated seven subsystems: pot sorting at 6 pots/second; AI-assisted diet dispensing at 3 pots/second; egg laying station at 450 pots per cage per cycle and 7 cycles per hour; AI-based egg detection processing 5,600 egg pots per row per hour; chimney sorting at 3 units/second on a continuous 24-hour cycle; lidding module; and egg capsule loader processing 8–9 trays per hour across 4 rows.• Co-designed egg detection hardware directly alongside the AI vision pipeline, optimising camera housing, illumination and pneumatic rejection actuator as a joint hardware-software outcome.• Applied GD & T, tolerance stack-up analysis, DFM and DFA from earliest design stages, significantly reducing rework cycles and improving assembly repeatability.• Authored SOPs, risk assessments and technical documentation enabling production staff to maintain and operate the system independently.
EDUCATION
P P Savani Vidhya Bhavan
Higher School, Science
Eurasia Institute - Berlin
Language Course, German Language
bbw Hochschule
Master of Science - M.Sc., International Technology Transfer Management - Industrial Engineering
Gujarat Technological University
Bachelor of Engineering - B.E., Electrical, Electronics and Communications Engineering
ABOUT AMITKUMAR J.
I am a Lead Mechatronics and Mechanical Design Engineer specialising in AI-integrated electromechanical automation systems. My work sits at the intersection of precision mechanical design, embedded electronics, machine vision and biological production systems.At BigSis (Zyzzle Ltd) in Reading I served as Lead Mechatronics Engineer and Module 1 Leader on a world-first automated insect rearing platform. I led a cross-disciplinary team of four engineers and took the central production system through four full development iterations — from early prototype to a production unit processing one million insects per week. The system integrates AI-based egg detection, automated diet dispensing, precision pot transport, and continuous 24/7 chimney sorting and lidding across seven integrated subsystems.Before BigSis I co-founded Infinity3D Technology LLP in India, where I designed and brought to market two industrial-grade FDM 3D printers — the DEV 200 and EDU 200 — from concept through commercial sale. My MSc research at BBW University of Applied Sciences in Berlin developed an original calibration methodology for 5-axis FDM printers using polar and spherical coordinate transformations, a problem with no standard solution in the additive manufacturing literature at the time.My technical foundation spans SolidWorks mechanical design, GD & T and tolerance stack-up analysis, DFM and DFA, PCB design and firmware development, stepper motor control, and hardware co-design with AI and machine vision pipelines. I am an member and IMechE member, with two research papers currently under peer review at Rapid Prototyping Journal and Access.Research profiles: Google Scholar — —
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