AliKhan

3D CAD Design Engineer

Suzuki • Full-time

Jun 2025 - Dec 2025 • 6 mos

Worked as a 3D CAD Design Engineer focusing on automotive structural components, specifically contributing to the chassis design of the Suzuki Ravi/Karvaan platform. Responsible for developing and refining complex CAD geometries, ensuring proper fit, strength, and manufacturability. Performed geometry optimization to improve structural efficiency while maintaining design constraints and production feasibility. Conducted basic FEA studies to evaluate stress distribution, deformation, and load-bearing performance of chassis components under different conditions. Collaborated on design improvements to enhance durability and reduce material inefficiencies. Key contributions include: 3D modeling of chassis components and assemblies Optimization of complex geometries for strength and weight balance Preparation of CAD models for simulation (FEA-ready geometry) Supporting design validation through simulation insights

Design & Analysis Engineer

Upwork • Self-employed

Mar 2024 - Nov 2025 • 1 yr 8 mos

Worked as a freelance Design & Analysis Engineer on Upwork, delivering 3D CAD modeling and engineering analysis services to international clients across multiple industries. Specialized in creating accurate parametric models, assemblies, and detailed manufacturing drawings using SolidWorks and other CAD tools. Handled projects involving complex geometries, product design, and mechanical components with a focus on functionality and manufacturability. Performed basic to intermediate FEA to evaluate stress, deformation, and structural performance, helping clients validate and improve their designs before production. Collaborated directly with clients to understand requirements, iterate designs, and deliver optimized solutions within deadlines. Maintained high attention to detail and ensured all deliverables were production-ready. Key responsibilities and achievements: * Delivered 3D CAD models (parts & assemblies) for various engineering applications * Created 2D drawings with dimensions and manufacturing details * Prepared simulation-ready models for FEA/CFD analysis * Optimized designs for weight, strength, and cost efficiency * Successfully completed multiple freelance projects with positive client feedback