ENGINEER
Mechatronics · Medical Devices · Robotics · Manufacturing

AjayNalla.

Engineering systems where mechanical precision meets embedded intelligence — from Class III implantable devices to parallel-kinematic robots.

ISO 13485 · FDA Class III Medical Devices Robotics & Automation R&D · Product Development CNC · Additive Manufacturing Remote · Available Globally
M.EngUniversity of British Columbia
B.TechJNTUH · Mechanical Engineering
Exp.Canada · India
Ajay Nalla — UBC M.Eng Graduation
01 — Profile

Built Different.

I am a Mechatronics and Mechanical Engineer operating at the convergence of hardware design, embedded systems, and regulated manufacturing. My work spans Class III invasive medical devices, cable-driven parallel robots, spherical manipulators, and large-format additive manufacturing systems.

With an M.Eng from the University of British Columbia and experience at Resonetics Canada as an R&D Mechanical Design Engineer — owning the full path from new product development and process validation through production line creation, QMS documentation, and manufacturing team leadership — I bring both deep technical capability and the discipline that safety-critical environments demand.

I design systems that close the loop: from mechanical architecture through electronics integration, firmware, and final validation in ISO 13485 environments. This cross-domain fluency — spanning R&D, manufacturing, robotics, and embedded systems — is rare, and it defines every project I take on.

5+
Years Engineering Experience
III
Class III Medical Device Work
6
Major Projects Delivered
ISO
13485 / QMS Regulated Env.
Class III implantable medical device — fingertip scale
Class III Implantable Device · Fingertip Scale · Life-Critical Engineering
02 — Portfolio

Selected Works.

01
Medical Device R&D · ISO 13485 · Class III

Resonetics — Implantable Device Systems

R&D Mechanical Design Engineer and Manufacturing Team Lead for Class III implantable battery systems powering pacemakers and neurostimulators (Abbott, Stryker, Boston Scientific) — within a fully ISO 13485 / FDA-compliant QMS. Reported directly to R&D Director, bridging product development and manufacturing while leading a team of 4 engineers overseeing 50 production workers. Owned the complete path from new product development through production — designing and validating new processes (IQ/OQ/PQ, DHF/DMR), automating manual manufacturing processes, and driving root-cause analysis and CAPA resolution. Delivered measurable impact: reduced scrap from ~30% to ~2% and cut critical process time from 40 hours to ~20 minutes through system redesign, automation, and equipment retrofitting.

ISO 13485 / FDA Class III Devices R&D Mechanical Design IQ / OQ / PQ DHF / DMR Lean Manufacturing CTQ Data Analysis Team Leadership
Scrap reduced ~30% → ~2% · Critical process time 40 hrs → ~20 min through automation and system redesign · Clients: Abbott, Stryker, Boston Scientific.
02
Construction Robotics · Large-Scale Additive Manufacturing

Concrete 3D Printer

Led design and development of a cable-driven concrete 3D printing system targeting ~10,000 sq ft construction scale. Progressed from independent consultant to project lead, managing a team of 5 engineers and 2 technicians. Owned mechanical and system design end-to-end — motion architecture, extrusion system, and vision-based path correction. Delivered a functional prototype within 14 months using under $100K of a $1M project budget through rapid prototyping, FDM-based development, and capital-conscious design.

Cable-Driven Parallel Robot Extrusion System Vision-Based Path Correction Motion Architecture Team Leadership Rapid Prototyping
Functional prototype in 14 months · Under $100K of $1M budget · Team of 7 · Targeting 10,000 sq ft construction scale.
03
Applied Research · Advanced Manufacturing · BCIT

BCIT — Advanced Manufacturing Research

Research Analyst at BCIT's Advanced Additive Manufacturing Technology Hub, working across the full spectrum of digital manufacturing — from 5-axis CNC machining to polymer and metal additive processes (FDM, SLA, HP MJF). Led material research on copper-infused PLA filaments for FDM, resulting in a published research study on improving mechanical performance and printability. Hands-on across CAM programming, toolpath optimization, and fabrication, with contributions to biomedical and robotic system development within applied research and product development initiatives.

HAAS 5-Axis CNC VERICUT CAM Simulation HP MJF Powder Bed FDM / SLA Metal Additive Published Research
Published research on copper-infused PLA · Full-spectrum digital manufacturing · Biomedical and robotic system contributions at BCIT's AM Technology Hub.
04
Parallel Robotics · UBC Research · System Redesign

Spherical Parallel Manipulator

Designed and developed a 3-DOF spherical parallel manipulator, followed by a full system-level redesign to resolve mechanical, actuation, and control limitations. Diagnosed structural misalignment, actuator underperformance, and electronics failure — then rebuilt end-to-end covering mechanical validation, actuator selection, power architecture, and embedded control. Delivered a fully functional platform with stable motion: servo actuation, Raspberry Pi control, inverse kinematics modelled in Adams, and dual control modes — physical potentiometers and a digital app with slider-based and predefined position control via inverse kinematics.

Parallel Kinematics Adams IK Simulation Raspberry Pi Control Servo Actuation Digital App GUI Potentiometer Control
Dual control modes — physical potentiometers and digital app. IK-driven predefined positions via Adams simulation. Full system redesign from failure diagnosis to functional platform.
05
Biomedical Robotics · Prosthetics · ISO 13485

Makershive — Bionic Prosthetic Hand

Core contributor to an affordable, high-performance bionic prosthetic hand — spanning mechanical design, system integration, and product optimization. Delivered 18 grip modes and ~8 kg load capacity using custom actuation and embedded systems. Drove cost reduction from ~$30K–60K to under $3K through CAE, rapid prototyping, and design simplification. Led coordination between mechanical and electronics teams, developed under ISO 13485 standards for real-world deployment in cost-sensitive markets.

Custom Actuators Bluetooth Control 3D Printed Body Custom EMG Electrodes ISO 13485 18 Grip Modes
Cost reduced from ~$30K–60K to under $3K · 18 grip modes · ~8 kg load capacity · Fully bionic hand developed to ISO 13485 standards for accessible deployment.
Patent Thumb Finger Swiveling System with Position Feedback — Indian Patent No. 403148 · Granted 05/08/2022 · KAL Bionics Private Limited · Application No. 202041016882
Publication Mechanical and Thermal Properties of Copper-Filled PLA Composites for FDM Additive ManufacturingJournal of Polymer Research · Springer · 2025
06
Vehicle Dynamics · Motorsport Engineering · BAJA

Formula & BAJA Motorsport

Designed, built, and competed with Formula-style kart and BAJA all-terrain vehicles as part of student design teams — working across the full vehicle lifecycle: chassis design, suspension geometry, powertrain integration, and vehicle dynamics tuning. Hands-on fabrication using lathe, milling, welding, cutting, and tube bending alongside CAD/CAE-driven design validation and CNC-machined custom components. Responsible for design engineering, cost analysis, budget planning, and compliance with BAJA technical rules and safety standards. Competed in SAE India BAJA — a large-scale endurance event with rigorous technical inspection validating both engineering design and build quality.

Chassis Design Suspension Geometry Powertrain Integration Lathe / Mill / Welding CAD / CAE Validation Budget Management
Full design-to-race cycle — chassis, suspension, fabrication, CNC components. Design Engineer and Costing Engineer — budget owner and compliance lead for BAJA rules.
03 — Career

Experience.

Feb 2024 — Present
Resonetics Medical Power
Mechanical Design Engineer · Surrey, Canada
  • R&D Mechanical Design Engineer in product development for Class III implantable lithium/Li-Ion batteries serving Abbott, Stryker, and Boston Scientific
  • Reports directly to R&D Director — bridges product development and manufacturing; leads 4 engineers overseeing 50 production workers
  • Reduced scrap from ~30% to ~2% and cut critical process time from 40 hrs to ~20 min through system redesign and equipment retrofitting — saving USD 1M+
  • Automated manual manufacturing processes using Lean Manufacturing; developed CTQ data analysis tools to identify trends and prevent production backlogs
  • Designed and validated manufacturing processes compliant with ISO 13485 & FDA regulations; created DHF/DMR documentation and robust traceability systems
Apr 2023 — Feb 2024
British Columbia Institute of Technology (BCIT)
Research Analyst — Applied Research · Burnaby, Canada
  • Hired by BCIT's Applied Research division for material research on FDM metal-filled polymer filaments; developed novel approaches to enhance mechanical properties
  • Led copper-infused PLA filament research resulting in a published research study on improving strength and printability
  • Managed Advanced Additive Manufacturing Lab; provided manufacturing support across metal, composites, SLS, and FDM processes for industry clients
  • Hands-on across 5-axis CNC (HAAS UMC 750), VERICUT simulation, HP MJF powder bed, and multi-material additive systems
Dec 2022 — Feb 2023
Industrial Pixel VFX
Mechanical & Electrical Designer · Vancouver, Canada
  • Designed and developed electromechanical systems for the film industry — clients include Marvel, DC, and major Hollywood productions
  • Responsible for full body scan rigs, face scanners, and mobile LiDAR systems for capturing actors and scenes to create digital doubles
Nov 2022 — Jan 2024
Archtype 3D · 14North Construction Ltd
Consultant Engineer (Mechatronics) · Saskatoon, Canada
  • Independent engineering consultant hired to develop a concrete 3D printer for construction — progressed to project lead managing 5 engineers and 2 technicians
  • Designed and developed a Cable-Driven Parallel Robot capable of printing 10,000 sq ft structures; delivered functional prototype within 14 months under $100K of a $1M budget
  • Owned motion architecture, extrusion system design, vision-based path correction, and tested 8×8 ft concrete 3D print samples
Oct 2019 — Aug 2021
Makers Hive Innovations
Mechanical Design & Support Engineer · Hyderabad, India
  • Core R&D mechanical design team member at an internationally recognised startup developing advanced bionic upper limb prostheses — designed, validated, and patented electromechanical mechanisms to ISO 13485
  • Drove cost reduction from ~$30K–60K to under $3K through CAE, rapid prototyping, and design simplification; delivered 18 grip modes and ~8 kg load capacity
  • Cross-functional collaboration with electronics team on control board design; engineered in-house testing strategies that accelerated ISO 13485 certification
  • Led coordination of additive manufacturing for prototype acceleration; monitored externally manufactured component quality
Mar 2019 — Aug 2019
Leap Robots LLP
Research Associate · Hyderabad, India
  • Mechanical designs for electronic enclosures, robot frames, and gearboxes; FDM in-house prototyping and assembly
  • Programmed Arduino and Raspberry Pi microcontrollers for robot control systems
Mar 2018 — Sep 2018
Eleation
Engineering Intern · Pune, India
  • Design validation using Ansys Workbench 18.1 — validated wind turbine blade design through CFD analysis with full documentation
  • Worked across Ansys Mechanical and Ansys Fluent simulation environments
04 — Capabilities

Technical Stack.

Mechanical Design
  • SolidWorks / CATIA / Fusion 360
  • GD&T and Tolerance Analysis
  • FEA — Structural & Thermal
  • Mechanism Design & Kinematics
  • DFM / DFA Principles
  • Technical Drawing & Detailing
Mechatronics & Embedded
  • Embedded C / C# / Python
  • Raspberry Pi & Arduino Systems
  • Servo & Stepper Motor Control
  • Sensor Integration & Signal Processing
  • PCB Schematic Review
  • Bluetooth / Wireless Comms
Manufacturing
  • 5-Axis CNC — HAAS Mill & Lathe
  • CAM — Mastercam / Fusion CAM
  • FDM / SLA / DLP Additive
  • HP MJF Powder Bed Fusion
  • Metal Additive Manufacturing
  • Metrology & Inspection
Robotics & Control
  • Forward & Inverse Kinematics
  • Parallel & Serial Manipulators
  • Cable-Driven Parallel Robots
  • MATLAB / Simulink
  • PID & Control Systems
  • Workspace & Singularity Analysis
Medical Device / Regulatory
  • ISO 13485 QMS
  • Class III Device Manufacturing
  • DHF / DMR Documentation
  • IQ / OQ / PQ Validation
  • CAPA & NCR Management
  • 21 CFR Part 820 Awareness
Tools & Methods
  • FMEA / Risk Management
  • Six Sigma / Lean Basics
  • Technical Report Writing
  • Project & Team Management
  • Linux / Windows / CLI
  • Git / Version Control
05 — Academic

Education.

Master of Engineering
University of British Columbia, Vancouver, Canada
Mechanical Engineering · Mechatronics · 2021 – 2023
Bachelor of Technology
JNTUH · Mechanical Engineering, Hyderabad
Mechanical Engineering · Robotics & Vehicle Projects
ISO 13485
Medical Device QMS — Industry Experience
Regulatory · Class III · Production Validation
06 — Contact

Let's Build Something.

Have a project in mind? Looking for a remote engineering partner? Get in touch — I respond within 24 hours.

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