Vaibhav Chaudhari

About Vaibhav Chaudhari

Versatile Mechanical Design Engineer with 5+ years of experience in 3D modeling, FEA…

Experience

1. Mechanical Design Engineer

   Holtec International

   Jan 2025 — Present · NJ, US

   Worked on designing large industrial heat exchangers and structural frames using PTC Creo, optimizing weld layouts and material selections. Reduced fabrication cost by 11% through requirement-gathering sessions and collaboration with thermal, structural, and manufacturing teams. • Created detailed ASME Y14.5-compliant 2D drawingas and parametric 3D models, improving design release accuracy by 95%. Used Windchill PLM to manage version control, drawing approvals, and engineering change notices across all project stages. • Performed FEA simulations in ANSYS for static loads, thermal stresses, and vibration response. Achieved 93% accuracy compared to physical test results, reducing physical prototypes by 2 and saving 3 weeks in the design-validation cycle. • Supported testing procedures including hydrostatic pressure, thermal soak, and modal vibration analysis. Analyzed results in MATLAB, identifying failure risks early and increasing test pass rate from 85% to 97% on pressure vessel assemblies. • Maintained and optimized BOMs using Excel (Pivot Tables, VLOOKUP) and ERP systems, resulting in a 14% material cost reduction. Coordinated with suppliers to apply DFM principles, reducing machining time by 9% on average. • Participated in cross-functional design reviews with thermal, structural, QA, and fabrication teams. Helped reduce engineering rework by 18% by incorporating early-stage feedback and ensuring compliance with ASME Section and client specifications.