B Bhanu
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Hi! I’m Bhanu — Mechanical Engineer

Specialized in new product development, fluid power systems, FEA, prototyping, and engineering validation.

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About

Mechanical Engineer and IFPS Certified Fluid Power Hydraulic Specialist with 5+ years of experience turning engineering concepts into manufacturable, validated products.

Background includes hydraulic-system and manifold development, high-pressure pumps, cylinder test equipment, structural FEA, DFMA, prototyping, and performance validation. I combine first-principles calculations with simulation and hands-on testing to make practical design decisions. I am currently completing my Master of Science in Mechanical Engineering at Northern Illinois University.

Skills

Product Development
NPD/EPD, Concept Development, DFM/DFA, Material Selection, Prototyping
Fluid Power
Hydraulic Circuits, Manifolds, Pumps, Cylinders, Valves, Filtration, Pressure-Drop Analysis
CAD & Drawings
3D/2D CAD, Assemblies, GD&T (ASME Y14.5), BOMs, Tolerance Stack-Up
Analysis
Linear Static FEA, Buckling, Hand Calculations, Design Optimization, Root Cause Analysis
Testing & Manufacturing
Test Fixtures, Pressure/Leak/Performance Testing, Sensor & DAQ Integration, CNC, Sheet Metal, Additive Manufacturing
Engineering Software
SolidWorks, Creo, Ansys, MATLAB, Automation Studio, Arduino/DAQ

Experience

Design Engineering Intern — Hydraulic Technologies

May – Aug 2026
  • Contributed to the development of a two-stage hi-low radial piston pump using engineering calculations and FEA-driven optimization.
  • Conducted analytical, FEA, and experimental buckling studies of high-tonnage aluminum hydraulic cylinders.
  • Designed and fabricated modular fixtures for cylinder cycle and side-load testing.
  • Performed competitor teardown analysis to compare design intent and component life ratings.

Graduate Research Assistant — Northern Illinois University

Aug 2024 – Present
  • Designed a compact, modular filtration test setup, improving leak tightness and measurement accuracy by 15%.
  • Integrated sensors, DAQ hardware, and control components for performance evaluation and validation.
  • Developed staged filtration concepts and optimized internal flow paths to improve efficiency and reliability.

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.

Projects

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Two-Stage Hi-Low Radial Piston Pump

Two-stage hi-low radial piston pump

Compact pump combining a gear-pump stage for low-pressure, high-flow operation with radial pistons for high-pressure operation.

  • 60 in³/min at 10,000 psi
  • Operates from a standard 15 A, 110 V circuit
  • FEA-driven component and valve optimization
Fluid Power FEA NPD

Cylinder Cycle & Side-Load Test Fixtures

Hydraulic cylinder cycle and side-load test fixtures with FEA results

Modular fixtures developed for safe, repeatable testing of multiple high-tonnage hydraulic-cylinder configurations.

  • Validated with FEA and hand calculations
  • Designed for high tensile loads and existing test chambers
  • PLC and limit-switch integration for automated cycling
SolidWorks GD&T Test Engineering

Hydraulic Cylinder Buckling Study

Hydraulic cylinder stress, buckling mode, and experimental test results

Analytical, FEA, and experimental evaluation of long-stroke, high-tonnage aluminum hydraulic cylinders.

  • Compared FEA results with ISO 13725 calculations
  • Studied multiple end conditions and boundary assumptions
  • Developed an updated long-stroke design methodology
Buckling Ansys ISO 13725

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

Contact

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