Kaustubh Dalmia

Mechanical Engineer at Sky Canoe

Developed and optimized 3D CAD models and 2D engineering drawings of aircraft assemblies, reducing design-to-manufacturing discrepancies and ensuring full compliance with aerospace standards. Designed and prototyped custom 3D-printed parts, achieving ~20% weight reduction while maintaining structural integrity. Performed advanced FEA on structural components to identify and mitigate stress concentrations and vibration risks, improving reliability and service life. Collaborated with cross-functional teams to iterate and validate designs, accelerating the concept-to-prototype cycle and supporting project milestones.

Research Engineer, CERC@MARC at McMaster Automotive Resource Centre (MARC) / CERC@MARC

Led design efforts on axial and radial flux motors in collaboration with EATON, contributing to aerospace electrification solutions that enhanced system efficiency. Developed precise 3D assemblies and 2D manufacturing drawings using aerospace standards and GD&T, reducing design-to-manufacturing errors and improving production accuracy. Conducted structural and thermal FEA simulations that identified critical stress points, enabling design optimizations that improved motor reliability and thermal performance. Assisted in motor assembly and testing to validate design improvements and shorten prototyping cycles with industry partners.

Lead UA Systems Testing Engineer at Invictus Defense Systems PVT LTD

Led the UAV testing team for the development of prototypes and MPV aircraft, including the tuning of the PID controllers which refined the final product making it more reliable and efficient. Developed 3D assembly drawings of aircrafts and 2D drawing for manufacturing of components. Products developed and showcased include LEAP, Sparrow, Jet Pack, and Target UAVs.

Systems Engineer at F-Drones PTE LTD

Led the manufacturing team, tasked with operations planning and timely delivery of products, during the tenure launched 2 significant products, HyperLaunch and HyperCopter. Headed the product development team, conceptualizing and designing composite and plastic parts for HyperLaunch and HyperCopter. Led the development of vision-based VTOL landing and added new features, also explored and tested various RF communication modules for long distance telemetry and video systems for more than 50 Km.

Teaching Assistant at McMaster University

Conducted Mechanical measurement labs for 250+ undergraduates, emphasizing Dimensional Measurement, Statistical Analysis, and Electrical Measurement.

Test Specialist and Fabricator at Quatlas Aeromodelling

Managed the electronics of the aircraft and extracted 6kg+ thrust under 1000 watts and secured 7th rank worldwide.

Lead CAD designer at OPUS team, SSERD

Led CAD design for a space habitat concept for 500 occupants, addressing space, artificial gravity, and energy production considerations.

Mechanical Engineer at Sky Canoe

Developed and optimized 3D CAD models and 2D drawings for aircraft assemblies, ensuring aerospace compliance; prototyped weight-optimized 3D-printed parts (20% weight reduction) while preserving structural integrity; performed advanced FEA to mitigate stress concentrations and vibration risks; collaborated with cross-functional teams to accelerate concept-to-prototype cycles and meet milestones.

Research Engineer at CERC@MARC, Canada

Led design efforts on axial and radial flux motors in collaboration with EATON, contributing to aerospace electrification solutions; produced precise 3D assemblies and GD&T-based 2D drawings to reduce manufacturing errors; conducted structural and thermal FEA to optimize reliability and thermal performance; assisted in motor assembly and testing to shorten prototyping cycles.

Lead UA Systems Testing Engineer at Invictus Defense Systems Pvt Ltd

Led the UAV testing team for prototype and MPV aircraft, including PID controller tuning to improve reliability and efficiency; produced 3D assembly drawings and 2D manufacturing drawings; notable projects include LEAP, Sparrow, Jet Pack, and Target UAVs.