design work portfolio

1. kumarnilay82@gmail.com
www.linkedin.com/in/nilay82
+917639690879
TOOL & PRODUCT DESIGN
PORTFOLIO
Nilay Kumar Kushwaha (B.Tech mechanical, post graduate in tool engineering)

2. About me
Hello
Thank for your time to have a glimpse on
my portfolio
I am a tool and product design engineer.
Design is about giving an imagination to the
creative way for better outcome.
My area of work is
• Tool & fixture design
• Aerospace components process planning
& manufacturing
• New product development
• 3D metal printing and rapid prototyping
Working at :-
MSME Technology Centre Bhubaneswar
Skills:-
CAD software UGNX Solid-works Catia
AutoCAD
Press tool design & Mould design
Sheet metal & Plastic product design
Process planning & tolerance stack up analysis
Additive manufacturing
Experiences:-
Make in India projects
Aerospace components of ISRO, HAL ,ADA
Press tool design of Patton international &
LPSC Bangalore
Plastic product development for IMMT
Bhubaneswar
Dental components design
Robotic arm project of Zuti engineering

3. contents
Product development
1. Dental Vernier caliper
2. Dental Bending tool
3. Solar panel cleaning gadget
4. Wheelchair for physically disabled
5. Agriculture equipment manadva
weeder
6. Mini Dal mil
Tool and fixture
1. 2”locknut -3cavity progressive press
tool
2. Lpsc blanking tool
3. Radius tool
4. Fin tools
5. Draw die
Aerospace components
1. Impeller with inducer
2. AINS cluster
3. Involute casing
4. Microsat baffles
5. 1 POL OPTION DUAL USER BEAM
6. 2 user cum tracking
7. Top platform
Robotic & Automotive
components
1. Robotic Joint-3
2. Robotic Joint-4 & 5
3. Connector Joint
4. Joint6-7
5. Sleeve And Bellow

4. PRODUCT DEVELOPMENT

5. Dental Vernier caliper
It is dental Vernier caliper. It is design
for additive manufacturing.
It is used to measure the geometry
and dimensions of tooth

6. Dental Caliper With Fixture Setup

7. Dental Bending Tool
It is a dental bending tool used to bend the dental clip wire. Four different tool design and manufactured
for different angles setup as per the application .

8. Solar Panel Cleaning Gadget

9. Wheelchair For Physically Disabled People

10. Agriculture Equipment Mandava Weeder
It is about five inches broad and can be operated
between two rows of crops. It removes the
weeds/unwanted grass and mixes them with the soil.

11. Mini Dal Mill

12. Tool design
 Design calculation
 Preparation of tool layout
 Design checklist and analysis
 Modelling and drafting
 Bill of materials
 Manufacturing of tool
 Components trail out

13. 2”locknut -3 cavity progressive press tool
• STRIP LAYOUT DESIGN

14. Preparation of die plate layout
• Cutting force calculation
• Stripping force calculation and
press tonnage calculation
• Die clearance calculation
• Determining the die plate
thickness
• Prepare the die plate layout
• Die set selection

15. Top & Bottom Half Assembly

16. 2”locknut -3cavity progressive press
tool assembly

17. Lpsc blanking tool

18. Fin tools

19. Radius cutting Tool

20. AEROSPACE COMPONENTS

21. Impeller With Inducer
Impeller with inducer is made of aluminum alloys
(AlSi10Mg) because AlSi10Mg is a typical casting
alloy with good casting properties and is typically
used for casting Parts with thin walls and complex
geometry. 3d printing reduces the product cost as
well as manufacturing time substantially.
Impeller with inducer used in the centrifugal
pump of jet engine. It rotates at very high rpm.

22. ANIS CLUSTER
It is one of the major component of GSLV satellite.
Beauty of this product is hollow structure
Aluminum Alloy (AlSi10Mg).
Weight of this component reduced by 1 kg as
compared to subtractive mfg. where the weight
would have been 3kg without changing its strength.
Manufacturing time by 3D printing is approx. 01-02
weeks whereas in case of subtracting mfg. it takes
approx. 04-05 months with different CNC machining
processes.

23. INVOLUTE CASING
Impeller with inducer is made of aluminum alloys
(AlSi10Mg) because AlSi10Mg is a typical casting alloy
with good casting properties and is typically used for
cast Parts with complex geometry. 3d printing reduces
the product cost as well as manufacturing time
substantially.
Involute casing is designed to take energy from
impeller and convert into pressure.

24. MICROSAT BAFFLES
Microsat is a part of small satellite in the 100 kg
class that derives its heritage from IMS-1 bus.
It is very thin cylindrical structure with a groove of 0.7mm.
It is made of aluminum alloys very light in weight also
exhibits very nice mechanical properties.

25. 1 POL OPTION DUAL USER BEAM

26. 2 USER CUM TRACKING

27. TOP PLATFORM

28. ROBOTIC & AUTOMOTIVE COMPONENT

29. ROBOTIC JOINT-3
Joint-3 is used in the robotic automation of pick and place robots. Aluminum alloy (AlSi10Mg) exhibit the good
strength, hardness and dynamics properties therefore is good for development of parts likes robots that can be
subjected high loads. Perpendicularity between two axial cylinder is maintain within the tolerance of 10micron.

30. ROBOTIC JOINT-4 & 5

31. Connector Joint & Joint6_7

32. Sleeve & Bellow