Hitanshu Shah.

Multi-Body platooning aerodynamics in StarCCM+

A full RANS CFD parametric study of multi-vehicle close-proximity aerodynamics across 18 configurations, using the DrivAer reference geometry in Estate, Fastback and Notchback variants — each in smooth and detailed underbody form.

Built and validated geometry, executed mesh-independence study, applied the K-ε turbulence model (benchmarked at –0.56% error vs. experimental data), and post-processed velocity fields, surface pressures, skin friction and wake structures. Findings quantified inter-body Cd and Cl deltas across all 18 runs, identifying configurations delivering 16–20% drag reduction in trailing bodies.

Race car instrumentation & CFD-to-track correlation

As Aerodata Engineer, designed and operated the on-car aerodynamic and thermal data acquisition system for a Formula Student race car — installing pressure taps, thermocouples, travel sensors, and load cells, with sensor positions defined directly from CFD output for valid simulation-to-physical correlation.

Operated the system across 6+ race events and 10+ test sessions, building a MATLAB post-processing pipeline from scratch and authoring session-by-session aero reports. Findings on Cp distribution, downforce, and thermal behaviour fed directly back into design and CFD model refinement.

FEA & topology optimisation in HyperMesh

End-to-end FEA workflow on a steel structural bracket: HyperMesh pre-processing, mesh-convergence study, linear static and modal analysis, then SIMP-based topology optimisation in Optistruct.

Optimisation converged at 18 iterations (VF = 0.41), and the OSSmooth-guided redesign delivered 10.2% mass reduction with safety factor 2.0 — translating to 13.8% per-part manufacturing cost reduction at a 1,000-piece batch. Demonstrates structured simulation discipline directly applicable to fluid-structure interaction work.

Robotic gripper assembly · SolidWorks

A 13-component multi-material assembly designed end-to-end in SolidWorks — from QFD-driven concept selection (Pugh Matrix scored 40/40) and FMEA risk analysis (RPN reduced from 120 → 90), through to fully dimensioned engineering drawings with BOM.

Applied DFMA principles to achieve 81% design efficiency. Complemented by professional CATIA V5 experience: 20+ vehicle design projects delivered as Design Manager at Bombay Motor Works, leading a team of 4 designers and 10+ supplier relationships.

2-DOF quarter-car suspension · MATLAB/Simulink

A validated 2-DOF quarter-car simulation in MATLAB/Simulink with full analytical derivation. Calculated Ks = 8,106 N/m and Ku = 90,243 N/m from target natural frequencies (1.1 Hz / 12 Hz), then ran a parametric sweep across 10 damping ratios to characterise dynamic response.