Mechanical solution engineering for commercial drones — structural validation of airframes and propellers, and design of the production system to build them at scale.
Structural work ran propeller life estimation and frame static/modal/fatigue analysis, iterating geometry with the design team. Production work mapped the assembly sequence into a modular line with optimised takt time, then built the SKU and part-coding logic that lets the warehouse and production floor track every module. Supplier development and EMS handover documentation closed the loop from design to scaled manufacture.
Note: renders above are personal Blender visualisation work, not the commercial product.
Beyond the airframe, the bulk of the work was the production system: a modular assembly area laid out for flow, ESD-safe workstations for the electronics and sensor build, and a part-coding / SKU system written in Qt C++ so the warehouse and floor can track every module by scan.
Assembly area & team
ESD workstation design
Assembly floorplan
Material-flow diagram
SKU software (Qt C++)
Assembly area
Mechanical design and packaging for the Bharat 100 drone battery — from the exploded CAD model through to the assembled pack.
Hitting 500+ units/month with a line that's affordable today meant designing for duplication — modular stations that can be cloned as demand grows, rather than one monolithic line sized for a future that may shift.
Drones mix mechanical parts, electronics and calibrated sensors — each with different revision behaviour. The SKU and part-coding system had to encode this cleanly enough for warehouse staff to use without engineering supervision.
Production-ready modular line design targeting 500+ units/month · validated airframe and propeller life estimates · SKU system in use for warehouse and WIP tracking · Shenzhen sourcing relationships established · NPI transferred to EMS partners.
