Prshanth

Solving complex design challenges through data, technology, and 12 years of engineering experience.

Experience Summary

I’m Prashanth, a Mechanical Designer with over 12 years of international experience delivering high-performance, production-ready engineering solutions. Specialized in SolidWorks, I have designed and delivered mechanical systems and transformer assemblies for clients across 🇩🇪 Germany, 🇦🇺 Australia, 🇯🇵 Japan, 🇮🇳 India, 🇦🇪 UAE, 🇶🇦 Qatar, and several 🌍 African regions.

My career spans diverse industries—energy (transformers), heavy machinery, shipbuilding, fuel and transport systems, cement and grain storage, and harbor machinery repair. Through precision engineering and automation, I have helped clients improve manufacturing efficiency, reduce costs, and accelerate delivery timelines.

As a CSWP-certified SolidWorks specialist, I’m proficient in Weldments, Sheet Metal, and Drawing Tools, producing IEC- and ISO-compliant 3D models and documentation. I manage the full project lifecycle—from concept through production—ensuring quality, precision, and on-time execution across multidisciplinary teams.

Beyond design, I specialize in CAD automation, developing DriveWorks configurators and C#-based automation tools that cut engineering workload by up to 90%. I integrate VBA, Google Apps Script, and SAP to automate BOMs, cost sheets, and data pipelines, seamlessly connecting design data with real-time manufacturing and supply-chain systems.

My focus is on building intelligent, repeatable digital workflows that make engineering more accurate, efficient, and scalable. I’m passionate about bridging mechanical engineering and software development to drive Industry 4.0 innovation through smart, automated design ecosystems.

I hold a Diploma in IT and am currently pursuing a Bachelor’s in Information Technology at the University of Moratuwa (expected 2025).

Fluent in C#, VBA, JavaScript, SQL, and Google Apps Script, I bring a software-driven approach to mechanical design.

I built this website to showcase projects that combine engineering precision with digital automation, demonstrating how data and design can work together to solve real-world engineering challenges.

Recent Projects

Showcasing advanced SolidWorks design, precision modeling, and real-world problem-solving.

Advanced sheet metal and weldments

This project showcases expertise in advanced sheet metal and weldment design, utilizing SolidWorks to create complex, high-precision fabrications. The scope involved engineering structural frames and enclosures, with a focus on manufacturability, cost-effectiveness, and structural integrity. Key responsibilities included creating detailed 3D models, developing flat patterns for CNC cutting, defining weldment cut-lists, and producing comprehensive fabrication drawings. The project highlights a deep understanding of material properties, welding techniques, and modern manufacturing processes to deliver robust and reliable mechanical solutions.

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Substation Australian Mining Project 30 Units 300kVA, 1000kVA, 2000kVA

Engineered a series of high-capacity containerized substations for a major Australian mining operation, delivering 30 units with power ratings of 300kVA, 1000kVA, and 2000kVA. The project involved the robust mechanical design and integration of heavy-duty switchgear and transformers to withstand harsh environmental conditions. Key responsibilities included structural integrity analysis, advanced thermal management, and optimizing equipment layouts for maintenance and operational safety within a containerized footprint.

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Container Solar Substation 20 units

Led the design and engineering of a compact, containerized electrical substation for mobile and rapid-deployment scenarios. This project, executed in Solidworks 2025, encompassed the complete integration of medium and low voltage switchgear, transformers, and sophisticated control systems within a standard 20ft container. Key responsibilities included structural frame design, equipment layout optimization, thermal management simulations, and the creation of a comprehensive documentation package for manufacturing and assembly. The resulting solution provided a turnkey power distribution system that significantly reduced on-site installation time.

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Pole mounted transformer 300 units export market.

Designed and oversaw the production of 300 pole-mounted transformers for the international export market. This large-scale project involved optimizing the mechanical design for cost-effective manufacturing and ensuring compliance with various international standards. Key responsibilities included creating detailed 3D models and fabrication drawings in Solidworks, coordinating with suppliers, and implementing a quality control process to ensure each unit met stringent performance and durability requirements.

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Reverse Engineering - Bearing Housing

Executed reverse engineering projects to digitize and replicate legacy components for which no CAD data was available. Using a combination of 3D scanning and precision measurement tools, existing parts were meticulously analyzed to create accurate, manufacturable CAD models in Solidworks. This process also involved creating 3D printed prototypes to verify form, fit, and function before committing to final production.

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Special 5 point hanger to lift amorphous core

Designed a special 5-point hanger for lifting amorphous cores, ensuring safe and efficient handling during manufacturing and assembly processes. The design was validated through FEA to guarantee structural integrity under load.

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Reverse Engineering - CAT Rim

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Kitchen Countertop Design Europe Clients

Precision-engineered kitchen countertops for residential clients, translating on-site laser measurements into production-ready 3D models and fabrication drawings. This project involved coordinating with on-site technicians, integrating third-party components like sinks and faucets, and using specialized CAD software to ensure a perfect fit and finish. The result was a streamlined workflow from measurement to installation, ensuring high-quality, custom-fit countertops.

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Twistlock reverse engineering using ios lidar scan

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Sheet Metal Enclosure / Sheet Metal Fabrication

Designed and engineered a busbar chamber using advanced sheet metal techniques in Solidworks. The project focused on creating a durable, modular enclosure for high-current electrical busbars, emphasizing ease of assembly and maintenance. Responsibilities included developing precise flat patterns for fabrication, ensuring proper clearances, and producing detailed assembly drawings.

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Kaizen Cart

Designed and implemented a 'Kaizen Cart' to improve workshop organization and efficiency. This mobile tool cart was developed to support lean manufacturing principles by ensuring that tools and components are readily accessible, reducing waste, and improving workflow. The project involved 3D modeling in SolidWorks, sheet metal design, and creating fabrication drawings to bring the concept to life.

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Amorphous Core Transformer Development

Developed amorphous-core transformers in collaboration with Metglas Hitachi (Japan) to improve energy efficiency and sustainability. This project involved using FEA tools to optimize the design, reduce material costs, and enhance the transformer's performance. The work included creating detailed 3D models and fabrication drawings to ensure precise manufacturing and assembly.

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Design Automation Project Samples

Examples of design automation projects that transformed manual SolidWorks workflows into intelligent, rule-based systems—cutting design time, improving consistency, and enabling rapid customization across product families.

Panel Radiator

Furniture

Distribution Transformer

AI-Assisted CAD Automation System

This project explores the intersection of Artificial Intelligence (AI) and mechanical design by integrating a Large Language Model (LLM) with the SolidWorks API using C#. The system enables users to generate parametric 3D CAD models through natural language commands.

For example, a user can type: “Design a racing bicycle in steel,” and the system automatically produces a production-ready model within SolidWorks.

The architecture operates through a secure sandbox environment, where the AI interprets user input, generates validated C# API code, and executes it safely inside SolidWorks. Each successful model generation is logged — capturing both the input and the resulting output — allowing the system to continuously learn and improve through feedback-driven refinement.

This project demonstrates how AI-driven design automation can transform traditional CAD workflows, making them more intuitive, efficient, and creative. It represents a step toward intent-based modeling, where designers describe what they want — and the system handles how it’s built.