Mechanical Engineering

& Machine Learning

Building robust mechanical systems and intelligent data pipelines. Experienced in bridging the gap between hardware design and data-driven insights to solve complex challenges.

Companies I've worked with

Projects Showcase

A selection of my work across interdisciplinary, software, and mechanical domains.

Mechanical Engineering

Design & Development of two stage gearbox

Designed and developed a 2-stage gearbox for a sugar industry from concept to delivery, performing all calculations, SolidWorks modeling, and GD&T implementation. Oversaw manufacturing coordination and delivered a fully functional unit, now successful in operation. The project ensured reliable power transmission with precise mechanical alignment and robust design.

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Mechanical Head - The Robotics Forum

Led the robotics team as Mechanical Lead for two consecutive years in the prestigious DD Robocon competition, designing and delivering two fully functional robots from concept to competition. Oversaw end-to-end mechanical development, including chassis design, mechanism innovation, manufacturing coordination, and rigorous testing.

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Design of Shafts, Keys & Couplings for Indian Railways

Designed and manufactured a precision shaft with integrated key and coupling system, ensuring reliable torque transmission and alignment. Applied GD&T and tolerance stack-up analysis to achieve proper fit.

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Experimental Analysis of Powder Mixed EDM of Super Alloys (Titanium, Hastelloy & Inconel) - ISRO Funded Project

Designed and executed an experimental study on Powder Mixed EDM (PMEDM) of three super alloys (Inconel 718, Hastelloy, and Titanium), funded by ISRO. Focused on optimizing process parameters to enhance material removal rate, surface integrity, and surface quality for aerospace applications.

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Design and Manufacturing of Flywheel Assemblies for heavy vehicles (Defence Project)

End-to-end design and fabrication of high-inertia flywheel assemblies for defence applications, focusing on rotational stability, material integrity, and precision balancing. Conducted stress and thermal analysis to ensure reliability under extreme operational conditions, while optimizing for weight and performance. Oversaw manufacturing, machining, and assembly processes.

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Computer Science

Simple lane detection

End-to-end TuSimple lane detection pipeline using RESA, CLRNet-style models, and LSTR transformer. Includes data cleaning, training, decoder tuning, TuSimple metric evaluation, visual reporting, and JSON export. Designed for Kaggle T4x2 with a production-ready notebook.

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Energy Consumption Prediction using Machine Learning

Energy consumption prediction system using historical data, time-based features (lags, rolling stats), and ML models including tree-based algorithms and LSTM networks. Evaluated with regression metrics; final solution delivers accurate forecasts to support grid management and consumer optimization.

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Lane Detection and Departure Warning System

Real-time lane detection and departure warning system using a lightweight CNN trained on synthetic road images. Processes video at 50+ FPS, fits lane curves, and tracks vehicle position with hysteresis-based alerts. Fully self-contained and production-ready for ADAS on modest hardware.

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Classic Sentiment Analysis on IMDb Movie Reviews

IMDb sentiment analysis pipeline using TensorFlow Datasets, EDA (word counts, word clouds), and lemmatized text preprocessing. Trained Naive Bayes, Logistic Regression, and SVM on BoW and TF-IDF; Logistic Regression with TF-IDF achieved 89.1% accuracy. Incorporated GloVe embeddings to showcase advanced techniques. Delivered reproducible, well-documented code with error analysis and industry-grade practices.

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Predicting Wine Quality with Several Classification Techniques

Wine quality prediction using ML on combined red/white datasets. EDA, binary target (>6 = good), key features: alcohol & acidity. Trained Logistic Regression, Random Forest, SVM, XGBoost; Random Forest achieved 0.86 AUC. Offers insights to optimize wine production.

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CycleGAN model for unpaired image-to-image translation

CycleGAN for unpaired image translation, implemented in a production-ready Jupyter Notebook. Includes generator/discriminator networks, training pipeline, visualization tools, and configurable hyperparameters. Demonstrates cycle-consistency with sample experiments and results.

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Interdisciplinary

Design of Haptic Bicycle Simulator for Immersive Indoor Cycling Experience

This project explores the development of a haptic feedback device that enhances indoor cycling by simulating real-world road surfaces,smooth asphalt, rough gravel, and block pavement, through a stationary bike. The experience is paired with a virtual environment that visually matches the simulated terrain. A compelling fusion of physical sensation and digital immersion experiences.

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Real-Time Control of a Robotic Arm via WebSocket & Wi-Fi

Developed a low-latency, web-based control system for a robotic arm using WebSocket and Wi-Fi communication, enabling real-time, secure, and wireless operation. Designed a responsive graphical user interface that allows intuitive, precise manipulation of the robot’s movements while incorporating safety protocols to prevent operational hazards.

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Robotics Capstone - Manipulation Control Stack

Developed a mobile robot system capable of precise object manipulation by synchronizing a 4-wheel omnidirectional base with a robotic arm for accurate end-effector positioning. Modeled the mobile base using a custom mobileRobot class in MATLAB, which converts wheel speeds into chassis twist and computes real-time pose updates via matrix exponential kinematics.

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Ajinkya Jadhav

About Me

Mechanical Engineer with a strong background in Designing, Manufacturing (Lean/DFMEA), Machine Learning and Data Analytics. 

With 2+ years of hands-on experience designing cooling systems, plastic & sheet metal parts, and electromechanical assemblies for energy and automotive applications. 

Proficient in CAD (SolidWorks, Creo, NX, CATIA) and FEA analysis (ANSYS/NASTRAN). 

Strengths in liquid-cooling EV charger design, GD&T/tolerance stack-ups, and DFM/DFA for sheet metal and injection molding in medium-to-high-volume production.

Experience in handling the lifecycle from requirements, CAD/FEA, 2D drawings, manufacturing release, collaborating with suppliers, government comliance testing and cross-functional teams. 

Passionate about leveraging data driven insights and rigorous engineering principles to solve challenging problems from concept to production.

Core Skills

Programming & Data

  • Python
  • MATLAB, R
  • Classification & Regression (XGBoost, scikit-learn)

Engineering & Simulation

  • SolidWorks, CREO, CATIA, Inventor
  • ANSYS (FEA)
  • GD&T, DFM/DFA

Machine Learning

  • Time-Series Analysis
  • Model Validation & Calibration
  • Feature Engineering

Hardware & Manufacturing

  • EV Chargers, Cooling Systems & Bio-Electronics
  • High-Volume Manufacturing
  • SPC & Process Capability (Cp/Cpk)

Work Experience

Professional roles and responsibilities.

Nidec Conversion

Manufacturing/Mechanical Engineering Intern | Cleveland, USA

  • Water-cooled EV charger and Battery Energy Storage System (BESS) enclosure design and FEA analysis.
  • Applied tolerance analysis for key interfaces and reviewed drawings.
  • Collaborated across cross-functional teams to meet reliability standards.
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Sterling Generators Pvt. Ltd.

Executive - Technical | Silvassa, India

  • Development of 30 & 60 kW EV-charger from concept to release.
  • Minimized rework through DFMEA reviews and problem-solving techniques (Lean Six Sigma, Fishbone diagrams, etc.).
  • Conducted pilot-build tests, government compliance tests and reviews and RCA on quality deviations.

TATA Autocomp Systems

Graduate Engineer – Product/Manufacturing | Pune, India

  • Designed cooling assemblies (radiators & charge air coolers) and released detailed CAD packages (for Tesla, Stellantis, John Deere, Mahindra).
  • Led cross-functional reviews to improve inspection and quality outcomes.
  • Conducted DFM/DFA reviews to align specs with tooling and production capabilities.
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Automotive Research Association of India (ARAI)

R&D Intern | Pune, India

  • Conducted emissions validation testing on alternative fuel engines; collected degradation data and supported component reliability analysis (Diesel-Ethanol/Diesel-Methanol).
  • Assisted in predictive modeling (ANN, KNN) to forecast system failures based on operating conditions and component wear rates.
  • Supported mechanical and electrical subsystem testing under dynamic loading conditions to qualify hardware for hybrid and hydrogen powertrain systems.

Rolls Royce Power Systems

Mechanical Intern | Pune, India

  • Supported design for marine engine cooling system components using SolidWorks.
  • Developed Python tools for predicting bearing lifecycles.
  • Participated in reliability assessments for cooling system durability.
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Rolls Royce project image
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3Deality

Founder | Pune, India

  • Operated a student-focused 3D printing service, delivering 50+ custom designed parts for college projects and prototypes.
  • Collaborated directly with clients to refine designs for printability, cost, and function, reducing material use by up to 30% through topology optimization and design suggestions.
  • Mastered end-to-end rapid prototyping: from concept sketches and CAD modeling (SolidWorks/Fusion 360) to print setup, post-processing, and final delivery.

Publications & Research

Hover over a card to see details.

Optimizing Hydrogen Engine Performance a Comparative Study of Lean & Stoichiometric Calibration Approach

Abstract

Hydrogen combustion in internal combustion engines offers numerous advantages, such as zero CO2 emissions and high flame speed, which make it a promising alternative fuel for green vehicle solutions . . .

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Experimental Investigation of Effect of Various Diesel-Ethanol Blends on In-Use Multi-Cylinder Engine Performance and Emission

Abstract

In India, B7 (a biodiesel mix of 7% by volume in diesel) has been approved for use in diesel engines. Due to the depletion of fossil fuel supplies and tight pollution requirements, alternative ...

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Impact of Hydrogen-Enriched CNG on Combustion Phasing, Fuel Efficiency, and Emissions in a Multi-Cylinder Spark-Ignition Engine under Varying Loads

Abstract

The present study considered the combustion, performance and emission characteristics of a spark-ignition engine running different blends of Hydrogen-Enriched Compressed Natural Gas ...

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Performance and In-cylinder Combustion Analysis of Gasoline Ethanol Fueled Spark-Ignition Engine

Abstract

Ethanol is widely recognized as a sustainable and eco-friendly alternative for spark-ignition (SI) engines, primarily due to its renewable nature and favorable combustion characteristics ...

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Diesel Ethanol Blends in Genset Engine: Ensuring Diesel-Like Performance at Reduced Emissions Using Optimal Cetane Enhancer-Based Additive Composition

Abstract

A reliable power supply forms the basis of the robust economic growth of a country. The unreliable power supply is one of the key factors driving the demand for generator sets (gensets) ...

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Hydrogen as a Carbon Neutral ICE Fuel for Future India

Abstract

Researchers are under pressure to investigate and discover ways to improve the efficacy and reduce emissions from ICE due to the depletion of energy resources and the growing concern over ...

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The Viability of Ammonia in the Automotive Sector: Challenges and Opportunities

Abstract

Ammonia has emerged as a promising alternative fuel for transportation because of its high energy density (NH3 has more hydrogen than propane in a similar size tank), simple and carbon-free combustion, and potential to produce sustainably . . .

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Relevant Coursework

A selection of graduate and undergraduate courses.

Graduate Coursework (UC San Diego)

Advanced Machine Learning

Design & Control of Haptic Systems

Research NanoEngineering

Introduction to Deep Learning & applications

Controls

Robotics

Biomaterials & Medical Devices

Introduction to Visual Learning (Robotics)

Digital Signal Processing

Design optimization for Additive Manufacturing

Principles of Medical Imaging

Data Science Programming

Recommender Systems & Web Mining

Data Science for Multiscale Biology

Energy Systems

Project Management

Undergraduate Coursework

Advanced Calculus

Robot Mechanics & Control

Object Oriented Programming

Engineering Design & innovation

Software Development

Mechantronics and Robotics

Machine Design

Fluid Mechanics

Thermodynamics

Strength of Materials

Hybrid Vehicles

Hydraulic Machines & Fluid Power

Dynamics of Machines

Data Science

Applied Electronics

Mechanical System Design

Material & Processes Engineering

Applied Thermal Engineering

Heat Transfer

Machine Design

Strength of Materials

Kinematics of Machinery

Manufacturing Processes

CAD/CAM

Mechanical Workshop

Beyond Engineering

When I'm not designing systems or analyzing data, I enjoy applying my skills to other creative pursuits.

3D Printing & Prototyping

I run a small 3D printing setup at home to design and print functional parts, from custom electronics enclosures to mechanical gadgets.

Exploring Historical Places

Exploring natural landscapes and capturing them through photography, is one of the hobbies trying to do currently.

Reading

I'm an avid reader of classic and modern science fiction.

Hiking & Backpacking

Getting outdoors to hike and explore new trails helps me disconnect and recharge my problem-solving mindset.

Get In Touch

I'm always open to discussing new opportunities in engineering and data science. Please feel free to reach out.

Contact Information

Let's connect and build something great together.

925.819.7941
San Diego, CA, USA