Senior Mechanical Design Engineer — Special Purpose Machine Development

Job Title Senior Mechanical Design Engineer — Special Purpose Machine Development Employment Type Contract / Freelance / Consulting Engagement (applicant-proposed duration, maximum 6 months) Industry Machinery Manufacturing | Special Purpose Machines | Coconut Shell Processing | Button Manufacturing Functional Area Mechanical Design | CAD Engineering | Machine Development | Manufacturing Engineering Location Primary work location: Remote (design phase). Physical visits required to Sanand GIDC (Ahmedabad) and Rajkot fabrication vendors. Total site visits estimated: 6-10 during the engagement until successful production is established. Role Overview Our client, a coconut shell button manufacturer based in Sanand GIDC, Ahmedabad, is developing a proprietary Coconut Shell Button Blank Cutting Machine (Model: CBM-001 V2) to solve a critical production bottleneck. The client already operates automated downstream processes but requires custom mechanical automation for the upstream blank cutting stage. We are hiring a Senior Mechanical Design Engineer on contract basis to convert the existing concept design into complete manufacturing-grade CAD drawings, provide engineering guidance during vendor selection in Rajkot, and support the fabrication, commissioning, and production ramp-up phases. This is a hands-on technical role requiring both design expertise and practical machine-building knowledge. The role involves designing and optimizing mechanical components and assemblies using FreeCAD, SolidWorks, or AutoCAD, ensuring manufacturability by Rajkot-based vendors, and adherence to standard engineering practices. The engineer will collaborate directly with the entrepreneur-owner and fabrication team to deliver a functional first-of-its-kind machine, and will remain responsible for design integrity until successful production is proven. About The Machine Being Designed CBM-001 V2 is a dual-head floating-head trepanning machine for cutting button blanks from coconut half-shells. Key technical characteristics: • Overall dimensions: 1200 × 750 × 1100 mm (working height ergonomically optimized) • Two independent cutting heads with 240 mm center distance • Each head features spring-loaded floating mechanism (8-10 mm float stroke) to adapt to shell curvature • Ring cutter (tungsten carbide, TiN coated, 1.0 mm wall) sizes 14L to 24L (interchangeable) • Pneumatic feed cylinders with 50 mm stroke, spring-compensated • HIWIN HGH25CA linear guides (4 blocks per head in box pattern) • Bowl seating: PU concave seat (Shore A 70-75) with 3-point pneumatic edge clamps • Cut methodology: 85% partial cut + ejector pin (8 mm hardened steel) • Spindle: 1 HP × 2, VFD controlled, 1800-3000 RPM variable • Dust extraction: transparent acrylic hood with 50 mm suction port, 25-30 m/s velocity • Control: Delta PLC + HMI with Gujarati language interface, IP54 enclosure • Safety: two-hand start, safety guard interlock, light tower, spindle overload protection Key Responsibilities • Develop and modify 3D mechanical models and assemblies in FreeCAD, SolidWorks, or AutoCAD for the complete CBM-001 V2 machine and all sub-assemblies • Perform detailed design reviews to identify and resolve potential issues in mechanical components — particularly the floating head mechanism, spring assembly, cutter mounting, and bowl clamping system • Generate and maintain complete technical documentation including 12-18 manufacturing drawing sheets, individual part drawings for all custom components, pneumatic circuit schematics, electrical schematics, foundation drawings, assembly sequence diagrams, and Bill of Materials with vendor part numbers • Optimize designs for performance (production output 25-70 blanks/min target), cost (client-controlled fabrication budget), and manufacturability by Rajkot-based special-purpose machine builders, while ensuring compliance with industry safety standards • Work closely with the client, fabrication vendor, and component suppliers to validate designs and incorporate feedback from all stakeholders • Support vendor selection process by evaluating fabrication capabilities of shortlisted Rajkot vendors, participating in vendor meetings, and reviewing vendor proposals • Conduct site visits to fabricator during production phase (Rajkot, 215 km from client location) as needed for progress review and issue resolution • Support machine commissioning at client site in Sanand GIDC, including trial run supervision, adjustment of floating head springs, calibration of pneumatic pressures, and operator training assistance • Rectify any design defects identified at any stage (fabrication, assembly, commissioning, production) at no additional cost to client • Provide all necessary design upgrades and modifications until successful production of 25-40 blanks per minute with 90% uptime is proven over a 30-day trial period • Document lessons learned during first prototype build for use in subsequent machine builds (client plans to build 5 more machines after prototype success) Required Skills & Qualifications • Proficiency in FreeCAD, SolidWorks, or AutoCAD for parametric modeling and assembly design is required • Minimum 8 years professional experience in mechanical engineering design, with focus on special-purpose machines is required • Practical understanding of pneumatic-driven machinery design and troubleshooting is required • Experience with mechanical engineering principles including tolerances, GD&T, material selection, machining processes, welding, and fabrication is required • Ability to interpret and produce technical drawings including sectional views, detail views, and manufacturing specifications is required • Strong problem-solving skills with attention to detail and root-cause analysis capability are required • Ability to travel to Rajkot (215 km from Ahmedabad) and Sanand GIDC as needed during the engagement • Effective communication in English and Gujarati / Hindi for interaction with vendors and client team • Willingness to accept accountability for design integrity until production success is established Preferred Additional Skills • Experience designing trepanning, boring, or drilling machines • Prior projects involving natural material processing (wood, ceramic, composite, leather, rubber) • Familiarity with HIWIN, THK, or NSK linear guide integration • Experience with SMC, Janatics, or Festo pneumatic components • Understanding of Delta or Mitsubishi PLC + HMI systems • Prior working relationships with Rajkot machine building ecosystem • Experience with CAD collaboration tools and version control systems • Understanding of dust extraction and industrial ventilation design Deliverables The engineer will deliver the following outputs during the engagement: • Sheet 1: Title block, revision history, general notes, BOM summary • Sheet 2: Plan view (top view) with complete dimensions • Sheet 3: Front elevation with dimensions • Sheet 4: Side elevations (left and right) • Sheet 5: Section A-A (longitudinal cutting section) • Sheet 6: Section B-B (transverse section) • Sheet 7: Detail X — floating head assembly exploded view • Sheet 8: Detail Y — bowl clamping and locating mechanism • Sheet 9: Detail Z — ring cutter with ejector pin assembly • Sheet 10: Pneumatic schematic with valve numbers and line sizes • Sheet 11: Electrical schematic with PLC I/O list and safety circuit • Sheet 12: Foundation drawing with anchor bolt positions • Optional Sheets 13-18: 3D isometric view, assembly sequence, custom part drawings, maintenance access drawing • Complete Bill of Materials in Excel with vendor part numbers, quantities, unit costs, and lead times • 3D model files in FreeCAD, SolidWorks, or STEP/IGES format for future modifications • Engineering notes documenting design decisions, tolerances, and assembly instructions • On-going engineering support until successful production is proven at client site ENGAGEMENT TERMS (IMPORTANT — READ CAREFULLY) This engagement is structured to attract only serious, technically confident, and quality-committed candidates. The following terms are non-negotiable: Term 1: Applicant Proposes Compensation The client does not disclose budget. Each applicant must submit their own fee proposal based on their assessment of scope, complexity, and expertise. Proposals must include: • Total project fee (all inclusive of design, revisions, site visits) • Breakdown of fee across project phases • Preferred compensation structure: fixed project fee OR monthly retainer OR hourly consulting • Site visit travel expenses (may be quoted separately or included in total) Term 2: Applicant Proposes Timeline (Maximum 6 Months) The client does not fix the timeline. Each applicant must propose their own delivery timeline based on their capacity and workload. The absolute maximum permissible timeline is 6 months from contract signing to complete design delivery. Applicants proposing shorter timelines with clear milestone breakdown will be preferred, provided quality is not compromised. The timeline proposed by the applicant becomes contractually binding upon contract signing. Term 3: Delay Penalty If the engineer fails to deliver as per their proposed timeline: • Weekly deduction of 2% of total project fee will be applied for each week of delay • Maximum penalty capped at 20% of total project fee • Delays caused by client (feedback delays, scope changes) are excluded from penalty calculation • All delay attributions will be documented in the project log signed by both parties