Hello, I'm
Abhay A Mulgund
Mechanical Engineer specialising in Design and Manufacturing
I am a passionate Mechanical Engineer, currently pursuing my Master's at Columbia University. My goal is to become a leader in bringing complex products from concept to reality. I possess a strong foundation in design and manufacturing, backed by proven hands-on experience in the electric vehicle industry. My work has involved designing high-performance electric motorcycles at Orxa Energies and developing robust autonomous ground vehicles (UGV/MGV) for defence applications.
Education
Aug 2024 - May 2026 (Expected)
Columbia University, New York
Master of Science in Mechanical Engineering
GPA: 3.71/4.0
2016 - 2020
MS Ramaiah Institute of Technology
Bachelor of Engineering in Mechanical Engineering (First Class with Distinction)
Career Experience
Jan 2021 - May 2024 (3 yrs 5 mos)
Senior Mechanical Engineer
Orxa Energies Private Limited, Bangalore, India
Product Line: High-Performance Electric Motorcycle
- Engineered structural components, performing FEA & bearing load calculations to achieve a 2.2 kg weight reduction.
- Finalized production-ready drawings with GD&T for precise manufacturing standards.
- Optimized component design, reducing assembly time by 2 hours per unit.
Product Line: Autonomous UGV (for L&T Defence)
- Designed and developed the chassis, suspension, and battery enclosures in Fusion 360, optimizing for weight distribution and IP65 compliance.
- Engineered precision sensor mounts for high-value sensor packages, consistently achieving <0.1° alignment accuracy.
Product Line: Manned MGV (for L&T Defence)
- Designed and optimized the top structural component, ensuring full compliance with high load-bearing and occupant safety standards.
- Utilized advanced design principles (Topology Optimization, FEA) to manage weight while maintaining structural integrity.
Sept 2020 - Dec 2020 (4 mos)
Mechanical Design Engineer
Eco Drives Intelligent Motor Vehicle, Bangalore, India
- Executed comprehensive system architecture development and DVP&R (50+ tests).
- Created and managed $50+ part assemblies and test plan timelines using MS Project.
May 2018 - Aug 2018 (4 mos)
Mechanical Engineer Intern
Tata Hitachi Construction Machinery
- Assisted in **failure analysis** of hydraulic systems and boom assemblies, contributing to a documented 5% reduction in premature component failures.
- Conducted full dimensional QC checks.
Technical Skills
Design Tools
SolidWorks
Autodesk Fusion 360
Siemens NX
GD&T
Simulation Tools
Ansys (FEA, CFD)
Comsol Multiphysics
Topology Optimization
FE Modeling
Manufacturing Tools
CNC Machining
Metal 3D Printing
Injection Molding
Casting
Laser Cutting
Programming & CAM
Matlab & Simulink
Mastercam
Python (Basic)
Microcontroller (Basic)
Featured Projects
A selection of academic and professional projects. Use the arrows to see more photos.
Vortex Navigator Autonomous Platform
Creative Machines Lab, Columbia University
- • Designing an innovative three-wheeled autonomous robot for outdoor leaf cleaning.
- • Integrating a dual-motor drive system and a novel radial inlet-axial outlet impeller for enhanced cleaning efficiency.
The FlowSure System (On-Body Drug Delivery)
Columbia University
- • Designed a modular on-body drug delivery system (OBDS) for large-volume (5-25mL) chronic care infusions.
- • Featured a reusable hub and disposable, pre-filled cartridge to reduce e-waste and improve patient independence.
- • System features a novel cantilever insertion mechanism and a spring-driven roller for safe, simple delivery.
MEMS Capacitive Microphone
Columbia University
- • Led design optimization using COMSOL Multiphysics and FEA.
- • Achieved a 40% reduction in mechanical stress and enhanced frequency response (20 Hz–20 kHz) through parametric analysis.
Sustainable Air Purifier Redesign
Columbia University
- • Cut part count by 28% and reduced non-recyclable content from 63% to 12%.
- • Applied Design for Disassembly (DfD) and replaced plastics with biodegradable PHA and cork.
- • Achieved a 48% improvement in environmental performance (LCA).
Biomedical Device Design - PULSE
Columbia University
- • Developing improved patient intake and assessment systems to reduce delays that negatively impact hospital efficiency and patient outcomes.
Quadrupedal Robot Design
Columbia University
- • Designed a lightweight acrylic and 3D-printed frame with a custom actuation system of 8 high-torque servos.
- • Achieved +/- 1° motion accuracy and 95% stability on uneven terrain via optimized gait mechanics.
Manufacturing System for NACA Aerofoil
Columbia University
- • Designed a manufacturing system for a two-part assembly (Titanium base, 3D-printed top) to cast a modified NACA0012H Aerofoil.
- • The final aerofoil is intended for use in a vertical axis wind turbine.
Human Centered Design - Industry Research Lab
Columbia University
- • A lab designed to bridge the gap between academia and industry by bringing real industry challenges into the classroom.
- • Worked on live projects from companies (e.g., Ford) and received feedback from professional engineers.
Carbon Management: CO₂ Capture System
Columbia University
- • Assessed a Point Source Capture (PSC) system for CO₂ emissions from a cement factory using Monoethanolamine (MEA).
- • Analyzed scenarios for Waste Heat Recovery (63.6% reduction) and Renewable Energy (96.9% reduction) in net emissions.
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AuraLife Critical Care Compression System
World Bank (TEQIP) Sponsored Project
- • Led design of a portable electro-mechanical ventilator to combat the COVID-19 crisis.
- • Featured a NEMA motor-driven AMBU bag compression system with integrated pitot tube sensors and closed-loop control.
Formula Student (FSAE) Lead
MSRIT
- • Optimized chassis via ANSYS FEA, increasing torsional rigidity from 2,800 to 3,220 N-m/degree.
- • Secured 27th place overall out of 69 participating teams at Kari Motor Speedway.
4x4 Two-Seater Rally Car Lead
MSRIT
- • Engineered a 4x4 drivetrain with an 800CC engine, achieving 250 N·m peak torque and a sub-10 second 0-60 mph time.
- • Designed a double-ladder chassis with a 15% increase in torsional stiffness.
- • Secured 12th place overall out of 35 participating teams.
Autonomous Solar Glider
MSRIT (Award-Winning)
- • Won "Best Project of the Year" from Dept. of Science & Technology & received KSCST/ICREATE grants.
- • Led design, aerodynamic analysis (Xfoil), and 3D printing of a 4-meter wingspan glider.
UAV Structural Enhancements (Edhitha)
MSRIT
- • Led team effort to enhance Air-titan structural integrity, resulting in a 40% increase in payload capacity.
- • Reinforced fuselage and wings with carbon fibre, reducing wing flexure by 25%.
Publications, Awards & Service
Research Papers
- "CFD Investigation of Space Re-entry Vehicle" Published in the "Journal of Analysis and Computation," a peer-reviewed UGC journal, ISSN: 0973-2861, Volume XIII, Issue IV, April 2020.
- "Design and Development of An Autonomous Unmanned Solar Powered Glider" Published in the KSCST Technical Compendium (2019-2020). Supported by Dept. of Science and Technology, Govt. of Karnataka & Govt. of India.
Paper & Poster Presentations
- “Structural Health Monitoring” - 3rd Intl. Conference on Fatigue Durability and Fracture Mechanics, V.T. University, 2019.
- “Supersonic Flow CFD Simulations of a Space Re-entry Capsule” - Pradarshana, MSRIT, 2019.
- “Industry 4.0” - V.T. University, 2018.
- “Edhitha Unmanned Aerial Vehicle” - Bangalore Tech Summit 2018, organized by the Govt. of Karnataka.
Awards & Honors
- Best Project of the Year Award - KSCST, Govt. of India.
- Spark-Up Idea Challenge Winner - ICREATE.
- Research Grant - World Bank (TEQIP) for "Mechanical Resuscitator Pressing Ventilator".
- Research Grant - KSCST for "Autonomous Unmanned Solar Powered Glider".
- 12th Place Overall (35 teams) - Rally Car Design Challenge.
- 27th Place Overall (69 teams) - Formula Bharat.
Social Service
- Volunteer, BHUMI (NGO) Contributed to educating underprivileged children in science subjects at local schools.
- Volunteer, Society of Mechanical Engineers (S.M.E) Actively organized seminars and social initiatives.
Get in Touch
I'm actively seeking new opportunities and collaborations. Please feel free to reach out—let's connect.