Ajay Nalla
Mechanical & Mechatronics Engineer · M.Eng, UBC
7+ years across Class III medical devices, robotics and advanced manufacturing in Canada and India. M.Eng in Mechatronics from UBC, an Indian patent, and peer-reviewed research in Springer's Journal of Polymer Research.
Career.
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Feb 2024 — Present
Resonetics Medical Power
Mechanical Design Engineer · Surrey, Canada
- 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
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Apr 2023 — Feb 2024
British Columbia Institute of Technology (BCIT)
Research Analyst — Applied Research · Burnaby, Canada
- 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
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Dec 2022 — Feb 2023
Industrial Pixel VFX
Mechanical & Electrical Designer · Vancouver, Canada
- 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
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Nov 2022 — Jan 2024
Archtype 3D · 14North Construction Ltd
Consultant Engineer (Mechatronics) · Saskatoon, Canada
- 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
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Oct 2019 — Aug 2021
Makers Hive Innovations
Mechanical Design & Support Engineer · Hyderabad, India
- 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
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Mar 2019 — Aug 2019
Leap Robots LLP
Research Associate · Hyderabad, India
- Designed enclosures, robot frames and gearboxes; prototyped in-house with FDM
- Programmed Arduino and Raspberry Pi robot controllers
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Mar 2018 — Sep 2018
Eleation
Engineering Intern · Pune, India
- 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
Research and racing.
Copper-filled PLA research · BCIT
Led material research on copper-filled PLA filaments for FDM, peer-reviewed in Springer's Journal of Polymer Research (2025).
Ran BCIT's Advanced Additive Manufacturing Lab across FDM, SLA, HP MJF and metal, and supported industry clients.
SAE India BAJA / Formula
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.
On the record.
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Patent
Thumb Finger Swiveling System with Position Feedback
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Publication
Mechanical and Thermal Properties of Copper-Filled PLA Composites for FDM Additive Manufacturing ↗
Education.
- Master of Engineering · University of British Columbia, Vancouver, Canada
Mechanical Engineering · Mechatronics · Sep 2021 – Aug 2022 - Bachelor of Technology · JNTUH · Mechanical Engineering, Hyderabad
Mechanical Engineering · Robotics & Vehicle Projects
What's stuck?
Tell me what isn't working. Not sure what you need? That's fine. Describe the problem and I'll tell you where I'd start.