Hrishikesh Rao

About Hrishikesh Rao

As a Mechanical Design Engineer with over 5 years of hands-on experience, I am driven by…

Experience

1. Product Design Engineer

   Glasbox

   Aug 2021 — Present · Bonney Lake, WA, US

   Led the mechanical design and testing of consumer electronics systems, focusing on product performance, manufacturability, and sensor integration.• Designed and optimized mechanical components in SolidWorks, CREO and NX ensuring manufacturability and strict adherence to SWaP-C constraints, cutting development cycle time by 20% and expediting product launches. • Conducted structural and thermal FEA simulations (Ansys, SolidWorks Simulation) to validate designs early, reducing prototyping iterations and cutting overall testing costs by 15%. • Developed compact consumer electronics enclosures incorporating optical sensors, electromagnetic drives, rotary encoders, and linear actuators, enhancing system efficiency by 30%. • Led failure analysis and root cause investigations using 8D, Fishbone, and FMEA methodologies, addressing mechanical, thermal, and electromechanical issues, and decreasing failure rates by 20%. • Performed thermal validation and reliability testing, including thermal cycling and ingress protection tests on compact enclosures, ensuring efficient heat dissipation and long-term durability under high-stress conditions. • Performed worst-case tolerance analysis between lens and image sensor to ensure optical axis alignment within ±50 µm, enabling consistent image quality across high-volume production.• Collaborated with cross-functional teams (Electrical and Electronics (EE), Industrial Designers, Manufacturing engineers) to refine mechanical designs, improving team synergy and reducing design iteration cycles by 20%. • Partnered with suppliers in Asia to optimize material selection (aluminum alloys, thermoplastics, composites), negotiating cost-effective alternatives that reduced material expenses by 15% while maintaining performance and durability.

Education

• Shri Bhagubhai Mafatlal Polytechnic

  Diploma, Mechanical Engineering

• Ira A. Fulton Schools of Engineering at Arizona State University

  Master of Science - MS, Mechanical Engineering

• University of Mumbai

  Bachelor of Engineering - BE, Mechanical Engineering