Mechanical Design & Robotics
My initial interest in robotics was sparked by videos of Boston Dynamics' humanoid robot, "Atlas". At the same time, I was an avid motorcyclist, and while exploring off-road trails, I noticed the way I shifted my balance and controlled the throttle and brakes to navigate the rough terrain. This gave me the idea for my first robotics project: a rover that could traverse land, water, and rocks. After graduating, I decided to pursue my passion for robotics even further by founding a start-up based on one of my college projects. This marked my entrance into the field of robotics and over the past seven years, I have gained experience from many projects.
During my co-op at Amazon Robotics, I helped transform a 3,200-part Automated Storage and Retrieval System (ASRS) from prototype into a mass-production design (30,000 units/year) by applying advanced sheet-metal design principles and GD&T for high-volume manufacturing. This effort led to a 12% (about $4,600 per machine) overall cost reduction. I also owned the development of a mirrored ASRS variant—reducing on-site deployment time by four hours—and worked with Agility Robotics to test their humanoid robot (Digit) in Amazon warehouses, ensuring safe, efficient integration. Additionally, I standardized 180+ meters of cable routing to lower cable costs by 40% (about $6,300 per machine) and bolster reliability. Whether traveling out-of-state to solve real-time manufacturing issues or optimizing fastener designs, I always focused on creating more efficient, scalable robotics solutions.
Project Overview
This research introduces the Multi-Modal Mobility Morphobot (M4), a bio-inspired robot capable of traversing complex, unstructured terrains by repurposing its appendages for multiple modes of locomotion. Drawing inspiration from animals (e.g., birds that use wings for both flight and climbing), M4 demonstrates an unprecedented level of “locomotion plasticity” by using the same components—wheels, legs, thrusters—in different ways to roll, fly, crawl, crouch, balance, tumble, and manipulate objects.
Key Contributions and Capabilities
Multi-Modal Mobility
M4 can switch among eight distinct modes, such as ground vehicle (UGV), vertical balancing (MIP), aerial flight (UAS), and quadrupedal walking, offering resilience in environments with varied obstacles.
Appendage Repurposing
Each “leg” has two actuated joints plus a shrouded propeller that doubles as a wheel. By reorienting these appendages, M4 can increase its thrust-to-weight ratio (for aerial flight), enhance traction (to climb steep slopes), or vault over large obstacles (via a tumbling maneuver).
Autonomy and Path Planning
Onboard computers and sensors enable M4 to autonomously choose its locomotion mode. A multi-modal probabilistic roadmap (MM-PRM) and A* algorithm guide M4 in deciding when to drive, fly, or morph mid-mission for optimal energy use and obstacle avoidance.
Applications
Search and rescue scenarios in disaster areas, space exploration, delivery in residential settings, and precision agriculture are highlighted as prime use cases for M4’s versatile design.
My Role: Mechanical Design Engineer
System Architecture & Chassis
I led the end-to-end mechanical design of the M4 platform, ensuring the main chassis, leg assemblies, and wheel–thruster modules integrated seamlessly. This included selecting lightweight yet robust materials (carbon fiber and fiber-inlay 3D-printed components) to maximize the robot’s strength-to-weight ratio.
Appendage Mechanisms
I developed the leg linkages and gear-driven wheel shrouds so that each propeller could quickly pivot to act as a thruster, wheel, or manipulator. My design ensures minimal added mass while maintaining strength for both flight and ground operations.
Modular Joint Design
The two-actuator hip mechanism was carefully sized and tested under different load conditions—like carrying onboard computers or traversing rough terrain—so the robot could reliably transform between modes without structural failures.
Prototyping & Testing
I coordinated mechanical prototyping, iterative testing, and revisions that led to the final, scalable design. This involved bench tests of each appendage, full-robot tests of structural integrity during flight and tumbling maneuvers, and stress analyses to guarantee reliable performance.
Through my work on M4’s mechanical architecture, I helped create a robust, morphing system that enables the robot’s multi-modal capabilities—expanding what is possible for future search and rescue, exploration, and service robotics.
One of my recent projects is the development of a CAD model of a multi-modal locomotion robot. This is a four-legged robot dog called Husky, which can walk, run, and jump on various terrains. The robotic dog also has a set of propellers attached to its knees that can allow it to morph itself by extending its legs to a quadcopter and fly. This gives the robot the ability to navigate through complex environments and overcome obstacles that would otherwise be impossible for a conventional robot. I developed the controls of the robot using MATLAB and Simulink, and I am currently working on developing a reinforcement learning model for the robot to decide what form of locomotion to use for the desired path. I aim to test the robot in real-world scenarios and demonstrate its versatility and adaptability. This project is also the topic of my master’s thesis, which I am pursuing at Northeastern University under the supervision of Professor Alireza Ramezani.
At the Silicon Synapse Laboratory at Northeastern University as part of my Research assistantship role, one of the most challenging and rewarding projects I worked on was the redesign of the head of a robotic snake for lunar applications. This project involved incorporating advanced perception systems such as LiDAR and IMU sensors to enable the snake to navigate and map the lunar terrain. I had to consider crucial factors such as cooling vents for the Nvidia Jetson, a powerful computer that runs the snake’s software, a mechanical latching mechanism for seamless connection between the head and tail, and strategically positioned cameras and LiDAR for SLAM functionality. SLAM stands for simultaneous localization and mapping, which is a technique that allows the snake to create a map of its surroundings while estimating its own position. The redesigned head of the snake improved its performance, reliability, and versatility, making it suitable for various lunar missions such as exploration, excavation, and construction.
A revolutionary Lighter Than Air (LTA) aerial surveillance drone designed to address a major challenge of low altitude aerial surveillance: limited flight time. The key to its impressive capabilities was its innovative LTA system, which canceled out the effects of gravity, allowing it to remain afloat without external force. Additionally, the drone was equipped with a sophisticated algorithm that drove its control system, allowing it to combat winds speeds of up to 10 m/s or 37km/h. To make the system self-sufficient, solar cells were positioned on the drone's wide surface area to provide extra power to the payloads and extend the flight time.
I had been working on my start-up, Grass Root Advanced Systems, for a few years before finally launching it. Over the past few years, I had explored various markets for our technology and worked hard to improve the product. Recently, I had focused on celestial applications. I scaled the product up so that it could carry small satellites and payloads up to 2000kg into the stratosphere (35km).
Patent filed with application number: 202041001185
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I was awarded INR 10,91,000 from Dassault systemès for the project, "Amphibious Rover for Disaster Rescue and Surveillance". As the leader of the team, I was responsible for designing and fabricating the product and our goal was to achieve mobility in all three mediums (land, air, and water) with a system of rovers. To ensure the rover could move effectively, we conducted extensive research and evaluated several different options before deciding on an optimal drivetrain mechanism. This mechanism provides an optimal combination of power, agility, and maneuverability, allowing the rover to traverse through slushy terrain with ease.
The prototype was composed of four integrated modular robots, each with its own specific task. I was also responsible for working on various domains that are important for robotics, such as mobility, computer vision, and autonomous flight of drones. By developing the locomotion of the legged rover, using OpenCV for detecting people and estimating distance with Intel’s RealSense LiDAR, and way-point navigation for autonomous flight of drones, I was able to successfully create the prototype and prove its viability.
Video of the prototype being tested
Proof of concept and idea generation model
Developed a mechanical design that focused on creating a robot with synchronous leg motion similar to that of a millipede. I used a series of servo motors connected to links to control the movement of its legs in order to replicate the movement of a millipede. I designed a mechanism to control the motion of the legs, as well as a control system to synchronize the motion of the legs. The goal of the project was to create a robot that could move like a millipede, with all of its legs moving in unison.
The Automatic Tire Inflation Project for Multi-Axled Trucks using Roller Follower Mechanism was a concept developed during Autodesk's Design week competition. The project sought to revolutionize the way truck drivers maintained their tires. This project utilized a roller-follower mechanism to automatically inflate the tires of multi-axled trucks as they traveled along the road. The project was awarded as the winner.
Patent filed with application number: 201941035447
The chief goal of the project was to build a light-weighted version of a VLM AS/RS that can reduce the cost and space requirements of conventional systems. To achieve this, I changed the traditional design for the inserter/extractor by using sliders instead of conventional rack and pinion gears. This significantly brought down the cost of the project by 35%, as the cost of 136 gears of 32 teeth each was replaced by just 12 pairs of horizontal sliders. Moreover, this design also improved the speed and accuracy of the system, as the sliders eliminated the backlash and friction problems associated with gears. The system was tested and validated using SolidWorks and MATLAB simulations, and the results showed that it can perform reliably and efficiently under various load conditions.
An automated storage and retrieval system (ASRS or AS/RS) consists of a variety of computer-controlled systems for automatically placing and retrieving loads from defined storage locations. AS/RS systems are designed for automated storage and retrieval of parts and items in manufacturing, distribution, retail, wholesale and institutions.
The shape of the drone’s cage works well by dispersing the impact load all throughout the cage structure. In addition to structure of the drone’s cage, using nylon 6/10 material rather than ABS or PLA facilitates better displacement on its frame links from 1.010e+01 mm to 2.431e+00 mm. Note that the collision energy is a kinetic energy, it is influenced by the weight and the velocity of the aerial vehicle. The technology has been extended to civil applications such as police services, search and rescue, and surveillance. Many experts expect that the developed world will be at the centre of a major change in the public use of drones. The term "regular icosahedron" generally refers to the convex variety, while the non-convex form is called a great icosahedron.
A proof of concept was developed and simulated in an indoor setting.
Patent filed with application number: 202041001185
The drone designed for the prototype is a scaled-up version of the proof of concept. It comprises of a new type of drive system that converts the motion generated from the propellers into angular momentum for the truncated icosahedron. This conversion is achieved through a set of links that gives the cage three degrees of freedom.
They are designed to fly and roll near people. These drones are equipped with several safety features that make them ideal for use over a wide variety of terrains. The outer cage is a modular structure that is built using individual connectors and links. If the module runs over an obstacle that causes one of its links to break, only the damaged links and connectors can be replaced, quickly by trained personnels. Secondly, this concept reduces cost and repair time.
The goals of this project were to develop a computer vision model that identified the subject of interest as input from the user and measured its distance from the camera using its inbuilt LiDAR.
For this project, I decided to use a combination of the two systems available on Intel RealSense to create a depth estimation system that would provide accurate depth measurements with less noise. The system was based on a combination of a laser-based Lidar and an Infrared (IR) light-based camera. The Lidar was used to capture the coarse measurements of the environment and the IR camera was used to capture the fine details and to remove the noise from the measurements. This was done by calibrating the two systems such that the measurements from the Lidar and the camera were in sync with each other. The output of the system was then used for various applications such as object detection and tracking, collision avoidance, and navigation.
“EFFI CYCLE” is a national-level competition in which we conceived, designed, and fabricated a three-wheel configuration vehicle powered by human and electric power that is capable of seating two passengers. We designed and developed this vehicle from scratch, and I took the responsibility of the design lead and the primary driver. The designed and fabricated vehicle must be aerodynamic, engineered for performance & safety, with ergonomic design to qualify for the technical inspection and be fit to race.
Efficycle is an annual event where engineers from all over the country design and fabricate a dual-seater trike, that will undergo a series of rigorous inspections, before being allowed to race. Each year the event takes place at Lovely Professional University (LPU), Punjab.
"EFFI-CYCLE is an initiative of SAEINDIA Northern Section with the objective of providing an opportunity for the students, to explore the “Environment-Friendly and Economical” solutions for the day-to-day mobility needs of people. The event task is to conceive design and fabricate a prototype of a three-wheel configuration vehicle, capable of seating two passengers and powered by human and-electric hybrid power." - SAE India.
Developed a mechanical test bench to simulate and calibrate a computer vision model that detected the presence of humans around a forklift in a warehouse and automated its braking. The main challenge of the design was to counter in the parameters like forklift's weight, which varies depending on the material it is carrying, the surface and the frequency of people crossing paths with the forklifts. To solve this challenge, I developed a system that would calibrate the computer vision model based on the forklift's weight and other variables. By testing different scenarios, I was able to ensure that the system was effective in detecting humans and accurately braking the forklift in different situations. The project was a success, and the test bench was able to accurately detect and respond to the human presence without any errors.
A project was pitched to Maruthi Suzuki (A popular car manufacturer in India) called "the soundless horn". The primary purpose of this product is to reduce noise pollution due to the unnecessary honking of vehicles on roads. Our solution is to make the horn inaudible to people outside a car, but audible only to passengers inside the car. We achieved this by making the horn sound travel in ultrasonic frequencies. However, when it reaches a car, it is converted into audible acoustic soundwaves that are then heard only by the passengers in the car. What makes our system cost-efficient is a very simple process of frequency conversion from acoustic to ultrasonic sound waves.
Patent filed with application number: 201941044334
Designed an STI hub: a sustainable IOT based smart vertical farming solution, to implement and test aquaponics systems in a localized environmental condition.
Hydroponics, aeroponics and aquaponics are all sustainable farming practices suitable for areas suffering from water scarcity and regions with dry climatic conditions. But Aquaponics is distinct from other sustainable farming because of its products being completely organic and additional cultivation of fish for profit. In aquaponics, additional aquaculture yield is generated by using a balanced and closed-loop system. This system becomes a closed loop by using the by-product of crop cultivation (aerated water) for aquaculture and using a by-product of aquaculture (Ammoniated water) for crop cultivation.
Smartphones are usually very efficient at dissipating heat because they use low-power-consuming processors that shouldn’t produce excessive heat. Occasionally if we are using GPS along with the internet turned on or using high capacity apps or games or are transferring a lot of data the phone will produce more heat than normal though it should be within tolerance levels. If we feel it's getting too hot or the heat is not going away then we usually give the phone a rest. By giving a rest we usually, close down all apps turn of data/Wi-Fi/Bluetooth/. We find that it cools down fairly quickly. It has been reported that certain cases will hinder the phone's ability to lose heat, though most cases should be ok. If our phone is always hot when doing normal operations, it may be that the battery is faulty or the PMS (power management system). The main object of the proposed invention is to design a stand-alone heat dispensing cum mobile phone holder for mounting in vehicles while using the GPS for navigation. It is so designed that the operation will be completely self-sustaining by not using any power from the vehicle itself. But through solar cells mounted on it. Heat dispersion through forced convection This stand-alone system has a cooling fan mounted right on top of the phone’s processor and battery, which are the major heat generation zones. Thus, they regulate the temperature by blowing air from the surroundings. This will bring the device’s temperature close to the ambient temperature. Self-sustaining heat dispersion system This mechanical system comprises a much-enhanced method of power generation for using solar cells. The cells are positioned in such a way that they are always pointed towards the light source. We have achieved this by placing the cells which will be infused in the rubber medium of the suction cup, that will be mounted on the glass surface of a car.
Patent filed with application number: 202041029853
Based on my extensive experience with 3D printers, I can confidently say that I am a skilled and knowledgeable user in this field. Over the past five years, I have used 3D printers extensively for my projects in the robotics segment predominantly for prototyping, which has provided me with a deep understanding of the technology and its capabilities. During this time, I have worked with a variety of different 3D printers, including dual extruders, single extruders, and branded models such as Mark Forged and Ender. In addition, I have printed a wide range of materials, including PLA, ABS, PETG, and TPU, which has helped me develop a broad knowledge of the technology. I have also gained significant experience in troubleshooting common issues that can arise during 3D printing, which has made me a highly skilled and resourceful user of this technology. Overall, my experience with 3D printers is impressive, and I am confident in my abilities to use this technology effectively and efficiently.