Kunal Patel

I’m a Mechanical Engineer passionate about building electromechanical systems that bridge hardware innovation and manufacturing scalability. With hands-on experience developing next-generation MEMS-based LiDAR scanners, semiconductor automation equipment and other personal projects, I specialize in mechanical design, rapid prototyping, system integration, and testing.

I have extensive background in designing and fabricating complex assemblies, including precision fluid dispensing systems, wafer handling robotics, and high-volume consumer products. My skill set includes SolidWorks, FEA, thermal analysis, MATLAB data modeling, electronics integration, and hands-on manufacturing techniques like CNC machining, 3D printing, and PCB design.

Portfolio: kunalhpatel.com

• Mechanical Design Engineer | Insync Mirror | July 2024- Present
  • Worked on the next generation of MEMS based Lidar Scanners
  • Developing a robotic system to automate assembly, featuring a precision fluid dispense system for controlled epoxy application and a vacuum-operated pick-and-place mechanism for accurate glass lid placement
  • Designed and manufactured a testing fixture to cycle device between -40*C & 105*C for 100 cycles
  • Designed drop test to simulate varying shocks of up to 2000g, while also measuring deflection of the device under acceleration
  • Performed a variety of optical tests on the device, using DAQ hardware, electric probes/oscilloscopes, and PSDs
  • Designed a fixture to automate the removal of a single MEMS die from the wafer level, using various pneumatic components
• LEAD MECHANICAL DESIGN ENGINEER | Empro | oct 2023- May 2024
  • Empro is an electric bike front wheel that can convert any bicycle into an E-bike within seconds, with the motor, batteries, and all electronics integrated inside the wheel. This was a Finalist, and Fan Choice Award winner for UCSB 2024 New Venture Competition.
  • As the sole Mechanical Engineer on the project, I created the design for the first prototype. This featured an electric skateboard motor with an integrated 7.2:1 reduction to increase the torque at the wheel. This also featured a custom battery pack, manufactured out of 39 18650 Lithium-Ion cells, in a 13s 3p configuration with a BMS integrated. Using FEA, I performed a structural analysis on all the parts to ensure they would all be able to withstand the necessary loads
  • Manufactured and assembled all the components together, using machine shop equipment such as lathes and CNC mills. Empro was successfully tested to drive the user up to 28 mph (legal limit), with an installation time of >30 seconds
  • Designed a mass production unit, with parts to be manufactured from high volume methods such as injection molding and die casting
  • Using CFD, thermal simulation tools, and thermodynamic principles, I designed and validated a cooling system for the motor and electronics, featuring a heat sink and air to air heat exchanger. Designed a PCB for the battery pack and electronics
• Atmospheric systems engineering intern | brooks automation | June 2023- September 2023
  • Worked on the design of Equipment Front End Modules used in the semiconductor wafer processing and transport industry
    • Specifically, I worked on the design for a wafer carrying End Effector, which was to be ESD Coated
      • Used FEA and Engineering Principles to optimize the design to reduce deflection at end by 40%
      • Designed and 3D Printed a system to catch wafers off an alignment system
      • Designed and manufactured testing fixtures to simulate cycling loading on ESD Pads, which is currently at a cycle count of >1,000,000
• Engineering Consultant | Avinger | June 2021- September 2022
  • Designed devices to treat Peripheral Artery Disease (PAD)-Conforming to ISO13485 standards
    • Specifically, designed a rotating limiting device with a clicking mechanism to provide tactile feedback for the user to guide a catheter through arteries, and a mechanism to flush PAD-inducing materials out of the catheter using hydraulic pressure, all while following DFM Principles for high volume components
      • Made machinist drawings from designed parts and assemblies following GD&T Procedures
      • Used EVT, DVT, and PVT procedures to validate products from proof-of-concept stage to mass production stage

• BS in Mechanical Engineering | University of California, Santa Barbara| 09/2020-06/2024