Akash Kharatmol

Category: Projects

  • Battery Potting Tooling

    Redesigned a potting jig concept using silicone and 3D-printed flexible components, demonstrating 50%+ reduction in cleanup effort and improved demolding ergonomics during evaluation

    What I did

    • Redesigned the tooling from foam-based jigs to a silicone-based approach with 3D-printed flexible components
    • Improved features to simplify demolding and reduce risk of damage during removal
    • Iterated design based on operator feedback to reduce cleanup effort
    • Created CAD models and documentation for consistent use and handoff
    • Built and evaluated prototypes to confirm workflow and performance

    Validation / Evaluation

    • Evaluated repeatability and workflow consistency across multiple runs
    • Verified improved demolding and cleanup workflow
    • Documented results and recommended implementation approach

    Results

    • Demonstrated more than 50%+ reduction in mold cleanup effort
    • Reduced mold remake frequency (evaluation-supported improvement)
    • Improved ergonomics and reduced handling variability


    Tools: Fusion 360, 3D printing (flexible parts), prototype build followed with iterations, documentation

    Note – This project is presented in a sanitized format to protect proprietary information.

  • In-House Tooling Library (CNC + 3D-Printed Production Jigs)

    I design and produce a wide range of in-house tooling used across multiple production stations, including CNC-machined fixtures and 3D-printed jigs. These tools support tight-tolerance assemblies, improve repeatability, and help operators work faster and more consistently.

    In a fast-moving manufacturing environment, small tooling improvements make a big difference. I build and maintain a library of jigs and fixtures—often designed quickly, iterated with production feedback, and standardized for repeatable use. Many tools are 3D printed for rapid turnaround, while others are machined in-house when tighter tolerances or durability are required.

    What I do

    • Design jigs/fixtures for multiple stations (alignment, assembly support, holding, protection, and inspection aids)
    • Use 3D printing for rapid prototypes and quick-turn production tooling
    • Machine high-precision fixtures in-house when required for alignment and tight tolerances
    • Iterate designs based on operator feedback to improve usability and reduce variation
    • Document setup steps and checks to ensure consistent daily use

    Impact

    • Faster turnaround on new tooling by designing and producing in-house
    • Improved station-to-station repeatability and reduced operator variability
    • Better handling support for delicate assemblies and tight-tolerance features

    Tools: Fusion 360, CNC milling (in-house), 3D printing, prototyping and iteration, production documentation

  • Laser Engraving Process Implementation

    Implemented laser engraving in the production workflow to replace ink-based pad printing, improving branding durability and enabling clear, permanent marking for patient-use identification and safety.\

    What I did
    • Developed and implemented a laser engraving workflow to replace ink-based pad printing
    • Defined engraving parameters and standardized setup to improve repeatability and reduce variation
    • Created marking layouts and supported documentation for production use
    • Implemented marking as part of the outgoing product workflow and supported operator adoption
    • Established checks to ensure marking readability and consistency for branding and patient-use needs


    Tools: Laser engraving equipment, CAD/marking layout, process development, production documentation.

  • 8-Board PCBA Programming Jig

    Designed and implemented a fixture that enables simultaneous programming of 8 PCBAs, improving throughput and repeatability while reducing operator handling.

    Programming PCBAs one at a time created a workflow bottleneck and increased handling variability. I designed and implemented a multi-board programming fixture to standardize alignment and connections, reduce setup time, and support consistent production use in a regulated manufacturing environment

    What I did

    • Designed a fixture layout that holds 8 PCBAs in consistent positions with repeatable orientation
    • Created CAD models and supporting documentation to enable production use and repeatability
    • Built and assembled the fixture and iterated design features based on real production feedback
    • Implemented the jigs into the workflow and supported operator adoption
    • Supported production documentation (setup steps, key checks) to ensure consistent results

    Validation and Verification

    • Verified repeatability of board placement and connection alignment across multiple runs
    • Confirmed workflow consistency (loading, programming cycle, unloading) with production operators
    • Documented key usage steps and checks to support reliable, repeatable operation

    Results

    • Enabled simultaneous programming of 8 PCBAs, removing a major bottleneck
    • Improved programming workflow repeatability and reduced handling variability
    • Increased throughput and supported smoother production flow


    Tools: Fusion 360, rapid prototyping, in-house fabrication and assembly, production documentation and implementation.

    Note – This project is presented in a sanitized format to protect proprietary information.