Bhimappa Shekharappa Walikar

Mechanical Engineer | Product Design & Electronics Packaging Specialist

Mechanical Engineer with 11+ years of experience in product design, electronics packaging, rugged enclosure development, and PCB mechanical integration. Skilled across the full product lifecycle—including requirements capture, concept design, prototyping, verification, qualification, and production transfer. Specialized in product design & development, thermal analysis, finite element analysis (FEA), and integration of mechanical and electro-mechanical components for Military, Aerospace, and 5G Radio Telecom industries.

Role: Design Engineer | Tools: SolidWorks, SolidWorks Simulation

• Engineered a MIL-qualified conduction-cooled enclosure compatible with 19” rack and wall-mount standards.
• Integrated heat-pipe technology to enhance thermal transport and performed detailed thermal simulations for conduction paths.
• Defined PCB outlines, stack-ups, and component layouts for COM Express, MXM, XMC, and Mini PCIe modules.
• Optimized internal module placement to streamline harness routing and reduce wiring complexity.

Role: Design Engineer | Tools: solidwork

• Designed a rugged dual-display console using a combination of precision machining and sheet metal fabrication.
• Applied ASME Section IX welding practices to ensure structural integrity and certification readiness.
• Delivered complete documentation including BOM, Master Drawing Index, GA drawings, and detailed part drawings with GD&T per ASME Y14.5.
• Managed the ECR/ECN process, updating components and drawings for prototype and production builds.
• Worked directly with customers to resolve fabrication drawing queries and improve manufacturability.

Role: Design Engineer | Tools: solidworks

• Designed a rugged enclosure meeting MIL-STD-810G mechanical and environmental requirements.
• Developed 3U VPX PCB layouts and custom backplane interfaces, coordinating closely with PCB designers.
• Engineered a convection-cooled enclosure with optimized airflow paths and integrated high-reliability fans.
• Ensured mechanical-to-electrical compatibility through ECAD/MCAD collaboration.

Role: Design Engineer | Tools: SolidWorks, SolidWorks Simulation (Thermal)

• Designed a 19” ruggedized conduction-cooled chassis meeting strict weight and protection requirements.
• Achieved IP62 protection (IEC-60529) through optimized sealing and structural design.
• Performed thermal calculations and simulations to validate heat dissipation performance.
• Led end-to-end mechanical development spanning machining, sheet metal, and casting processes.

Role: Design Engineer | Tools: SolidWorks, Teamcenter PLM

• Designed enclosure compliant with IP62, EMI/EMC shielding, and random vibration requirements for rugged EW environments.
• Created PCB outline, critical component layout, and heat-sink design with improved thermal dissipation.
• Performed thermal and vibration analysis to validate structural integrity.
• Developed and managed the BOM and executed release activities via Teamcenter PLM.

Role: Design Engineer | Tools: SolidWorks

• Engineered an IP68-certified compact cable gland with UV-resistant design for outdoor environments.
• Selected materials using PA66 polymer matrix to meet mechanical, sealing, and environmental requirements.
• Managed the entire product lifecycle from concept → design → validation → production.
• Supported the injection molding process, tooling coordination, and production release.

Role: Mechanical Design Engineer | Tools: SolidWorks, CREO, HFSS (if applicable), AutoCAD

• Designed Orthomode Transducer (OMT) and Diplexer waveguide components used in high-frequency RF communication systems for defense and aerospace applications.
• Created precision waveguide geometries ensuring proper mode isolation, insertion loss performance, and structural rigidity for environmental compliance.
• Coordinated closely with RF and Microwave engineers to convert electromagnetic design requirements into manufacturable mechanical models.
• Developed 3D CAD models and engineering drawings for waveguide components including OMTs, diplexers, elbows, adapters, couplers, and flanges per MIL / IEEE standards.
• Conducted thermal, vibrational, and structural evaluations
• Designed mechanical architecture for ATE (Automated Test Equipment) stations, integrating electronic modules, RF switching hardware, waveguide assemblies, and test fixtures.
• Ensured ergonomic layout of ATE stations, supporting ease of wiring, RF routing, accessibility, and maintenance.
• Prepared complete engineering documentation, including BOMs, assembly drawings, wiring layouts, waveguide routing diagrams, and test fixture designs.
• Supported prototype builds, RF alignment, and collaborated with manufacturing teams for machining of waveguide components with tight tolerances.
• Managed design changes through ECR/ECN processes, ensuring traceability and compliance with PLM requirements.