Likhith Kumar Dasari
Mechanical Design & R&D Engineer
CAD · Product Development · Simulation · Additive Manufacturing · Engineering Automation
I develop engineering solutions where practical design, manufacturability, simulation, and digital workflows work together to improve product performance.
This is me.
Mechanical design, research thinking, and digital manufacturing in one workflow.
I am a Mechanical Design and R&D Engineer based in Germany, with a Master’s degree in Industry 4.0 from SRH Berlin University of Applied Sciences. My engineering background combines hands-on mechanical product development with research-driven exposure to simulation, additive manufacturing, and digital engineering workflows.
My professional experience began with custom mechanical product development, where I worked on concept design, CAD modeling, sheet metal design, fabrication support, assembly, testing, engineering drawings, and BOM preparation. This gave me a practical understanding of how design decisions affect manufacturing, assembly, cost, feasibility, and real-world product performance.
During my master’s and research work, I expanded this foundation into advanced manufacturing and engineering automation. I worked on TPMS-based heat sink research, CFD and thermal simulation, lattice design, and PrintMind, a structural-intelligence 3D printing workflow that connects CAD processing, simulation-based severity evaluation, and slicer-level print parameter optimization.
WHAT I BRING
Design thinking with engineering depth.Practical Design Thinking
From early concepts to CAD models, drawings, fabrication support, assembly considerations, and testing.
Manufacturing Awareness
Design-for-manufacturability, sheet metal constraints, BOM preparation, enclosure design, and fabrication requirements.
Analytical Engineering
Simulation, thermal analysis, structural evaluation, CFD studies, and engineering reasoning for better decisions.
Digital Manufacturing
Additive manufacturing, slicing workflows, lattice structures, TPMS design, and print-parameter optimization.
Engineering Automation
Engineering calculations, workflow scripting, data handling, and rule-based technical logic.
Engineering Stack
Platforms, solvers, manufacturing workflows, and engineering outputs I use to move from concept to validated product decisions.
Design & CAD Platforms
Mechanical design, CAD development, sheet metal design, engineering drawings, and implicit lattice modeling.
SWSolidWorks
NXSiemens NX
FCFreeCAD
nTnTopology
Simulation & Solver Tools
FEA, structural validation, thermal simulation, CFD interpretation, and simulation-supported design decisions.
ANANSYS
CCXCalculiX
Additive Manufacturing Workflow
Slicing workflow integration, lattice-based design, manufacturability evaluation, and print-parameter optimization.
PSPrusaSlicer
FDMFDM
DfDfAM
TPTPMS/Lattice Design
Programming & Engineering Tools
Engineering calculations, workflow scripting, data handling, and rule-based logic for technical applications.
PYPython
CC
C#C#
Engineering Output
Manufacturing-ready documentation, fabrication support, assembly awareness, and design-for-manufacturability communication.
DREngineering Drawings
BOMBOMs
DOCTechnical Documentation
REVDesign Reviews
WORK EXPERIENCE
Detailed engineering roles and research work.Master’s Thesis / Research Project — PrintMind
SRH Berlin University of Applied Sciences
Developed PrintMind, a software-assisted engineering workflow for structural intelligence in 3D printing. The project connects CAD processing, loading condition definition, simulation-based severity evaluation, and slicer-level print parameter optimization.
- Built a CAD-to-slicing workflow that processes CAD models, defines loading conditions, evaluates structural severity, and generates optimized print settings.
- Integrated Python, FreeCAD, PrusaSlicer workflow, and CalculiX-based simulation into one engineering pipeline.
- Implemented rule-based decision logic to adapt infill strategy based on structural severity and material-aware criteria.
- Designed the workflow to support manufacturable print decisions instead of relying only on uniform default slicing settings.
- Internal testing on one case showed up to 56% print-time reduction and 50% material reduction compared with the baseline print configuration.
Research Intern — Additive Manufacturing
SRH Berlin University of Applied Sciences
Conducted additive manufacturing research on TPMS-based heat sinks for single-phase immersion-cooled data center applications, focusing on digital design, thermal performance, manufacturability, and CFD-based evaluation.
- Developed a digital TPMS heat sink study for immersion-cooled data center processors using SP5 socket constraints and a high-heat-load design case.
- Compared gyroid, diamond, Kelvin, and honeycomb lattice structures based on flow behavior, thermal performance, surface area, manufacturability, and support requirements.
- Used nTopology for implicit TPMS geometry generation and CFD-based conjugate heat-transfer evaluation.
- Evaluated CuCrZr as a suitable LPBF material due to its high thermal conductivity, strength, and better processability compared with pure copper.
- Identified gyroid as the most balanced structure because it improved fluid mixing and thermal uniformity while avoiding channelized honeycomb flow behavior.
Design Engineer
Uniscient Engineering Ltd
Worked on custom mechanical product development from concept design to fabrication, assembly, and testing for application-specific engineering systems.
- Developed mechanical design concepts for a drone-mounted seed ball dispenser intended for afforestation in hard-to-reach areas.
- Created 3 individual design concepts as part of a 6-concept team evaluation and supported final concept selection based on feasibility, weight, and cost.
- Designed sheet metal casing, internal slots, and assembly-oriented mechanical elements for a biomedical waste disposal machine.
- Designed enclosure elements for a refrigerated mobile vending vehicle and prepared engineering drawings and BOMs to support manufacturing and installation.
- Supported design refinement by considering fabrication feasibility, assembly requirements, cost awareness, and manufacturability.
SELECTED PROJECTS
Selected engineering work across structural 3D printing, thermal management, additive manufacturing, and practical mechanical product development.
PM
Structural Intelligence for 3D Printing
PrintMind
A simulation-guided CAD-to-slicing workflow for adaptive infill and manufacturable print optimization. PrintMind connects CAD processing, loading condition definition, structural severity evaluation, and slicer-level decision logic to support smarter 3D printing workflows.
- CAD model preparation and loading-condition definition
- Severity-based structural interpretation
- Rule-based adaptive infill decision logic
- Slicing workflow integration for optimized print settings
- Internal test case showed up to 56% print-time reduction and 50% material reduction compared with baseline configuration
PythonFreeCADPrusaSlicerCalculiXCAD ProcessingAdaptive Infill
View Case Study
01
PrintMind
Structural Intelligence for 3D Printing
Python · FreeCAD · PrusaSlicer · CalculiX · Adaptive Infill · Rule-Based Optimization
02
TPMS Heat Sink Research
Single-Phase Immersion Cooling
nTopology · CFD · CuCrZr · LPBF · TPMS · Thermal Simulation
03
Custom Mechanical Product Development
Concept-to-Fabrication Engineering Work
SolidWorks · Sheet Metal · Engineering Drawings · BOMs · Fabrication Support
EDUCATION & CERTIFICATIONS
Academic and mechatronics foundation.M.Eng in Industry 4.0
SRH Berlin University of Applied Sciences · Focus: Robotics, Additive Manufacturing, Automation
Siemens Mechatronic Systems Certification Program — Assistant
Siemens Mechatronic Systems Certification Program — Associate
Have an engineering opportunity in mind?