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Leo Panda
Mechanical R&D Engineer
PROFESSIONAL SUMMARY
Mechanical R&D Engineer with 6+ years of experience developing electromechanical products from concept through validation and production release. Strong background in CAD, FEA, GD&T, DOE, and DFM, with a proven record of reducing defects, accelerating prototype cycles, and lowering product cost in high-volume manufacturing environments.
SKILLS
SolidWorks
GD&T
Finite Element Analysis
Design of Experiments
Tolerance Stack-Up Analysis
DFM/DFA
Prototype Testing
MATLAB
Minitab
PROFESSIONAL EXPERIENCE
Nordex Motion Systems
Industrial AutomationElectromechanical Products
Minneapolis, MN
Mechanical R&D Engineer
Product DevelopmentDesign Validation
Apr 2021 - Present
- Led design and validation of electromechanical assemblies for industrial automation products, reducing prototype iteration cycles by 25% and supporting on-time launch of two new platforms.
- Performed tolerance stack-up, FEA, and root cause analysis on thermal and vibration failures, cutting field-return defects by 18% within twelve months.
- Partnered with manufacturing and suppliers to release DFM updates, lowering machined component cost 12% and improving first-pass yield from 91% to 97%.
- Created test fixtures and verification plans for life-cycle and environmental testing, enabling design signoff three weeks earlier than the baseline schedule.
AeroTherm Consumer Technologies
Consumer HardwareThermal Systems
St. Paul, MN
Mechanical Design Engineer
CAD DesignSupplier Collaboration
Jul 2018 - Mar 2021
- Designed sheet metal and plastic components in SolidWorks for consumer hardware, achieving 98% drawing release accuracy and shortening ECO turnaround time by 20%.
- Built DOE-based prototype test plans to evaluate airflow and structural performance, identifying a fan bracket redesign that improved thermal margin by 14%.
- Supported supplier qualification and pilot builds across three vendors, resolving dimensional issues that reduced incoming inspection rejects by 30%.
- Authored BOMs, GD&T drawings, and engineering change documentation, helping cross-functional teams transition five product revisions into production without schedule slips.
SELECTED PROJECTS
Battery Enclosure Thermal Optimization - Project Lead
Nov 2023 - Feb 2024
- Developed an aluminum battery enclosure concept for a mobile robotics platform, using thermal simulation and prototype testing to reduce peak cell temperature by 11%.
- Defined sealing geometry, fastener strategy, and serviceability features, enabling assembly time reduction of 16% during pilot build evaluations.
- Coordinated design reviews with electrical and manufacturing teams, closing 24 action items and delivering a validated prototype within a ten-week schedule.
Modular Vibration Test Fixture - Mechanical Engineer
May 2022 - Aug 2022
- Designed a modular fixture to improve repeatability of vibration testing for compact actuators, increasing setup consistency and reducing technician preparation time by 35%.
- Integrated interchangeable mounting interfaces and datum controls, allowing one fixture family to support six product variants without additional tooling purchases.
EDUCATION
University of Wisconsin-Madison
ABET AccreditedMechanical Engineering
Madison, WI
Bachelor of Science in Mechanical Engineering
Sep 2014 - May 2018
Senior design focused on product development, machine design, heat transfer, and experimental methods.
Leo Panda
Mechanical R&D Engineer
PROFESSIONAL SUMMARY
Mechanical R&D Engineer with 6+ years of experience developing electromechanical products from concept through validation and production release. Strong background in CAD, FEA, GD&T, DOE, and DFM, with a proven record of reducing defects, accelerating prototype cycles, and lowering product cost in high-volume manufacturing environments.
SKILLS
SolidWorks
GD&T
Finite Element Analysis
Design of Experiments
Tolerance Stack-Up Analysis
DFM/DFA
Prototype Testing
MATLAB
Minitab
PROFESSIONAL EXPERIENCE
Nordex Motion Systems
Industrial AutomationElectromechanical Products
Minneapolis, MN
Mechanical R&D Engineer
Product DevelopmentDesign Validation
Apr 2021 - Present
- Led design and validation of electromechanical assemblies for industrial automation products, reducing prototype iteration cycles by 25% and supporting on-time launch of two new platforms.
- Performed tolerance stack-up, FEA, and root cause analysis on thermal and vibration failures, cutting field-return defects by 18% within twelve months.
- Partnered with manufacturing and suppliers to release DFM updates, lowering machined component cost 12% and improving first-pass yield from 91% to 97%.
- Created test fixtures and verification plans for life-cycle and environmental testing, enabling design signoff three weeks earlier than the baseline schedule.
AeroTherm Consumer Technologies
Consumer HardwareThermal Systems
St. Paul, MN
Mechanical Design Engineer
CAD DesignSupplier Collaboration
Jul 2018 - Mar 2021
- Designed sheet metal and plastic components in SolidWorks for consumer hardware, achieving 98% drawing release accuracy and shortening ECO turnaround time by 20%.
- Built DOE-based prototype test plans to evaluate airflow and structural performance, identifying a fan bracket redesign that improved thermal margin by 14%.
- Supported supplier qualification and pilot builds across three vendors, resolving dimensional issues that reduced incoming inspection rejects by 30%.
- Authored BOMs, GD&T drawings, and engineering change documentation, helping cross-functional teams transition five product revisions into production without schedule slips.
SELECTED PROJECTS
Battery Enclosure Thermal Optimization - Project Lead
Nov 2023 - Feb 2024
- Developed an aluminum battery enclosure concept for a mobile robotics platform, using thermal simulation and prototype testing to reduce peak cell temperature by 11%.
- Defined sealing geometry, fastener strategy, and serviceability features, enabling assembly time reduction of 16% during pilot build evaluations.
- Coordinated design reviews with electrical and manufacturing teams, closing 24 action items and delivering a validated prototype within a ten-week schedule.
Modular Vibration Test Fixture - Mechanical Engineer
May 2022 - Aug 2022
- Designed a modular fixture to improve repeatability of vibration testing for compact actuators, increasing setup consistency and reducing technician preparation time by 35%.
- Integrated interchangeable mounting interfaces and datum controls, allowing one fixture family to support six product variants without additional tooling purchases.
EDUCATION
University of Wisconsin-Madison
ABET AccreditedMechanical Engineering
Madison, WI
Bachelor of Science in Mechanical Engineering
Sep 2014 - May 2018
Senior design focused on product development, machine design, heat transfer, and experimental methods.
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