B Bhanu

Hi! I’m Bhanu — Mechanical Engineer

Curious by nature, who loves learning how things work — and making them better.

Bhanu portrait

About

Every idea starts as a sketch — a few lines on paper, a spark of curiosity. Over the years, I’ve learned to turn those sketches into something real: precise, manufacturable, and meaningful.

With 4+ years of experience in product design and R&D, I’ve led projects ranging from developing products for mobile fluid power systems to designing and testing advanced filters for air purification and cleaning. Now, as a Master’s student in Mechanical Engineering at Northern Illinois University, I’m deepening my research expertise while exploring diverse fields that connect design, experimentation, and innovation.

Skills

CAD & Design
DFM/DFA, GD&T, NPD / EPD
Analysis
FEA, CFD, Material Optimization, Root Cause Analysis
Manufacturing
CNC Machining, Additive Manufacturing, Sheet Metal
Software
Ansys, SolidWorks, CATIA, Blender, MATLAB, Arduino/DAQ

Experience

Graduate Research Assistant — Northern Illinois University

Aug 2024 – Present
  • Built a compact, modular ozone test setup; improved leak tightness and accuracy by ~15%.
  • Evaluated ozone removal filters at low temperature/humidity; integrated DAQ for real‑time data.
  • Developed multi‑stage filtration and flipping mechanisms for long‑term efficiency studies.

Mechanical Engineer Intern — APSCO, Inc.

Jun – Aug 2025
  • Designed a destructive inlet air filter system; took design from concept to prototype.
  • Led prototype test plans and equipment selection for key parameters validation.
  • Reduced size by 27% and extended service lifetime by 15× with staged filtration.

Mechanical Design Engineer — Design Cube Engineering Solutions

Jul 2021 – Aug 2024
  • Designed hydraulic reservoirs with integrated cooling/filtration for bulk feed trailers.
  • Optimized manifolds, reducing hoses/leak paths; cut part count & weight by 15–20%.
  • Performed FEA to save 10–17% material; created 3D/2D CAD, drawings, and BOMs.

Compact Ozone Test Train

Compact Ozone Test Train

Evaluating ozone filters, modular packed‑bed with O‑ring seals, custom pressure/flow measurement, DAQ integration.

  • ↑ measurement accuracy ~25%
  • Leak‑proof, compact, serviceable
  • Polypropylene for ozone resistance
Materials Arduino/DAQ

Multistage Inlet Air Filter (1000 CFM)

Multistage Inlet Air Filter

Heavy dust filtration, Cyclonic pre‑cleaner + panel filter, sheet‑metal design for easy top‑side service.

  • ↓ size & weight 35%
  • ↑ service lifetime 15×
  • 70% dust removed pre‑filter
SolidWorks Sheet Metal

Smart Conveyor: Orientation & Alignment

Smart Conveyor

Flipping mechanism and adjustable alignment holder for U‑shaped parts

🎬 Watch Video
  • ↑ orientation accuracy, ↓ manual handling
  • Serviceable with off‑the‑shelf parts
AC Gear Motor Automation

Hydraulic Die‑Punch Machine

Die Punch

Precision die & punch for aluminum sheets; 4″ hydraulic actuator (5″ stroke, 12,500 lb at 1,000 psi).

  • Clean edge quality; 16 parts/min
  • Rigid frame, quick service
Machine Design Hydraulics

80CC Motorized Bicycle

80CC Bicycle

Hybrid pedal/engine drive with 10–44 gear ratio for hill climbs; vibration‑isolating clamps.

🎬 Watch Video
  • Fuel efficiency ~55 km/L
  • Extended range and terrain capability
Powertrain Fabrication

Multipurpose Farming Machine

Farming Machine

Modular 750W electric tool carrier for ploughing, weeding, spraying; quick‑swap attachments.

🎬 Watch Video
  • ~8 hrs per charge
  • Compact, corrosion‑resistant frame
Design, FEA Electromechanical

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