AjayNalla.
When your hardware won't work, I make it work. I diagnose what's broken, redesign it, and prove it works — from Class III medical devices to parallel robots.
Experience
Solved
Regulated
I Make Stuck Hardware Work.
I'm the engineer teams call when hardware is stuck — a prototype that won't perform, a line throwing scrap, a robot that won't hold position.
I work across mechanics, actuation, electronics and code, so I find the real root cause instead of patching one subsystem. UBC M.Eng Mechatronics, ISO 13485 regulated experience, Indian patent holder, Springer-published.
How I work: Diagnose → Redesign → Prove. I start with a fixed-scope diagnostic, so you know what's wrong before you commit to a fix.
Problems Solved.
Resonetics — Class III Implantable Battery Line
A production line for implantable batteries (pacemakers, neurostimulators) running ~30% scrap, with one critical process taking 40 hours.
Led a system-level redesign — automated manual steps, retrofitted equipment, built CTQ data tools — inside an ISO 13485 / FDA quality system, leading 4 engineers and a 50-person production floor.
Scrap ~30% → ~2%. Critical process 40 hrs → ~20 min.
Spherical Parallel Manipulator
A 3-DOF spherical robot that couldn't move stably — structural misalignment, underpowered actuators and failed electronics.
Diagnosed each failure, rebuilt the mechanics, re-selected actuators, redesigned the power architecture, and wrote Raspberry Pi control with inverse kinematics modelled in Adams.
Stable motion with two control modes — physical potentiometers and an app with slider and preset-position control.
Bionic Prosthetic Hand — Makershive
Bionic hands cost $30K–60K — out of reach for most amputees in cost-sensitive markets.
Custom actuation, 3D-printed body, CAE-driven simplification and a patented thumb-swivel mechanism, developed to ISO 13485.
Under $3K, 18 grip modes, ~8 kg load capacity.
Concrete 3D Printer
Printing house-scale concrete structures normally needs a massive, expensive gantry.
Designed a cable-driven parallel robot, custom extruder and vision-based path correction; went from consultant to project lead of 5 engineers and 2 technicians; used rapid prototyping to move fast.
Working prototype in 14 months using under $100K of a $1M budget; 8×8 ft concrete prints; targeting 10,000 sq ft structures.
BCIT — Advanced Manufacturing
Metal-filled PLA filaments are weak and hard to print reliably.
Led material research on copper-filled PLA; ran BCIT's additive lab across FDM, SLA, HP MJF and metal; supported industry clients.
Published in Springer's Journal of Polymer Research (2025).
BAJA / Formula Motorsport
Build a race-legal all-terrain vehicle that passes SAE BAJA technical inspection on a student budget.
Chassis, suspension, powertrain integration, fabrication and costing; budget owner and rules-compliance lead in a team of 25.
Passed all safety tests and competed at SAE India BAJA.
Got a problem like these?
See How I WorkExperience.
- R&D mechanical design for Class III implantable batteries used in pacemakers and neurostimulators
- Report to the R&D Director; lead 4 engineers and a 50-person production floor
- Cut production scrap from ~30% to ~2% and critical process time from 40 hrs to ~20 min through system-level redesign
- Automated manual steps, retrofitted equipment and built CTQ data tools — all inside an ISO 13485 / FDA quality system
- Led material research on copper-filled PLA filaments — published in Springer's Journal of Polymer Research (2025)
- Ran the Advanced Additive Manufacturing Lab across FDM, SLA, HP MJF and metal; supported industry clients
- Hands-on with 5-axis CNC (HAAS UMC 750) and VERICUT simulation
- Designed electromechanical capture systems for film — clients include Marvel, DC and major Hollywood productions
- Built full-body scan rigs, face scanners and mobile LiDAR systems for creating digital doubles
- Hired as a consultant to build a concrete 3D printer for construction; became project lead of 5 engineers and 2 technicians
- Designed a cable-driven parallel robot targeting 10,000 sq ft structures; working prototype in 14 months using under 10% of the project budget
- Owned motion architecture, extruder design and vision-based path correction; printed 8×8 ft concrete samples
- Core R&D mechanical designer on an affordable bionic prosthetic hand; designed, validated and patented mechanisms to ISO 13485
- Cut cost by more than 90% through CAE, rapid prototyping and design simplification; 18 grip modes and ~8 kg load capacity
- Worked with the electronics team on control boards; built in-house tests that sped up ISO 13485 certification
- Designed enclosures, robot frames and gearboxes; prototyped in-house with FDM
- Programmed Arduino and Raspberry Pi robot controllers
- Validated a wind turbine blade design with CFD in Ansys Workbench, Mechanical and Fluent
Technical Stack.
Design & CAE
- SolidWorks / CATIA / Fusion 360
- GD&T & Tolerance Analysis
- FEA — Structural & Thermal
- Mechanism Design & DFM
Mechatronics & Controls
- Parallel & Serial Kinematics
- Servo & Stepper Control
- Raspberry Pi / Arduino · Python / C
- Adams / MATLAB Simulation
Manufacturing
- Automation & Equipment Retrofit
- Lean & CTQ Data Analysis
- 5-Axis CNC & CAM
- FDM / SLA / HP MJF / Metal AM
Medical Device QMS
- ISO 13485 / FDA
- Class III Device Production
- IQ / OQ / PQ Validation
- CAPA & FMEA
Education.
Master of Engineering
Bachelor of Technology
What's Stuck?
Tell me what isn't working. I reply within 24 hours.