SURAJ THOKAL
I'm a passionate Mechanical Engineer with over 4 years of hands-on experience in product design and development, specializing in CAD modeling, simulation, and the practical application of core engineering principles to solve real-world challenges. My career has been built around driving innovation, meeting tight deadlines, and ensuring the successful execution of technical projects from concept to completion.
Currently, I work in the Research and Development department at ABB Electrification, where I contribute to the mechanical design of New Product Development (NPD) initiatives. I have developed expertise in concept development, precise 3D modeling and 2D drafting, prototyping, DFMEA-based design reviews, test strategy planning, and managing final production releases - efforts that have consistently driven cost savings and improved product performance. I also oversee 3D printing operations to accelerate rapid prototyping and support innovation across teams.
Beyond engineering, I am deeply passionate about Biomimicry - drawing design inspiration from nature to develop efficient, sustainable, and functional solutions. I believe that many of the problems we face today have already been solved by nature, and integrating these insights into modern mechanical design is both a creative and responsible approach to innovation.
Linkedin recommendations
Suraj is an exceptional mechanical engineer with a passion for innovation. His rapid learning abilities allow him to swiftly grasp intricate concepts and apply them effectively. Beyond technical prowess, Suraj is known for his amicable nature and strong collaboration with colleagues. His work consistently reflects high quality and precision. In summary, Suraj is an asset to any engineering team, combining technical excellence with interpersonal skills.
Sylvain Trottier
R&D Manager at ABB
Having the opportunity to work closely with Suraj, I have been able to observe his drive, how he takes ownership and initiative in all tasks he undertakes. He does great work and I recommend him without hesitation.
Kelley McAlpine
Product Manager at ABB
Highly recommend Suraj for his exceptional mechanical design skills! He is a dedicated and hardworking professional always eager to tackle new challenges. His passion for innovation shines through in his work. A valuable asset to any team!
Mathusan Sachchi.
Manufacturing Engineer at ABB
I highly recommend Suraj as a Mechanical Engineer.
His attention to detail and innovative solutions greatly contributed to our project successes. Suraj is a valuable asset to any team, showcasing strong problem-solving skills and dedication.
Reshika Paramanathan
Product Specialist at ABB
I had the pleasure working with Suraj for three years at ABB Electrification, EML division. We hired Suraj initially as Mechanical Engineering Intern and immediately recognized his multiple mechanical design talents. Being eager to learn and hands-on with prototypes, Suraj has professionally grown quickly and played an important role as Mechanical Design-Engineer within our R&D team. He can handle multiple projects under difficult circumstances and always respected deadlines. I would hire Suraj again in a heartbeat and believe he would be an asset to any organization.
Trinh Vu
R&D Mechanical Lead at ABB
ABB
Mechanical Engineer
Research and Development, ABB
Nov 2024 — Present . 0 yr 9 mos
Designing and developing new Emergency Lighting products (NPD) by conducting feasibility research, evaluating mechanical concepts, creating 3D models, prototyping, performing DFMA and FMEA analyses, followed by rigorous testing and commissioning.
Managing multiple projects simultaneously, including preparing project plans, material, cost, and time estimates, and ensuring timely project completion through effective coordination with various teams.
Developing detailed design specifications, 3D models, and 2D drawings in compliance with GD&T standards for manufacturing components such as sheet metal, castings, and plastic injection-molded parts, while working closely with the purchasing team.
Defining test objectives, developing procedures, executing tests, and compiling detailed reports to ensure compliance with CSA, UL, and ASTM regulations.
Conducting component inspections and generating comprehensive inspection reports (F24) to verify fit, tolerance, and installation, ensuring adherence to design specifications, DFMA guidelines, and regulatory compliance.
Coordinating product launches in collaboration with production teams, overseeing pilot runs, installation testing, and quality control inspections to ensure smooth production and product integrity.
Leading the mechanical redesign and standardization of customer-special and Buy and Sell projects, as well as implementing cost-saving initiatives for continuous improvement projects.
Collaborating with cross-functional teams, including Quality, Marketing, Production, and R&D project managers, to ensure design feasibility, resolve mechanical issues, and develop optimal solutions that balance performance, cost, and manufacturability.
Managing and maintaining all engineering data within the Windchill PLM (Product Lifecycle Management) system, utilizing 3D parametric modeling software (PTC Creo) to support design and development processes.
Mechanical Designer
Research and Development, ABB
Feb 2024 — Nov 2024 . 1 yr 10 mos
Mechanical Intern
Research and Development, ABB
May 2022 — Feb 2023 . 0 yr 10 mos
Responsibilities
Montreal, Quebec, Canada
Experience
Chameleon Innovations
Service Centre Technician
Mar 2021 — Apr 2022 . 1 yr 2 mos
Repairing, maintaining, and assembling rolling tarp systems and machinery components to ensure optimal performance and safety.
Fabricating, assembling, and inspecting mechanical products and subassemblies in compliance with technical specifications and production plans.
Preparing, cutting, drilling, grinding, and shaping metal components using mechanical tools and equipment.
Designing and fabricating jigs, tools, and fixtures to support welding, drilling, and cutting processes, improving efficiency and safety.
Ensuring compliance with workplace safety standards, including CSST regulations, by maintaining work areas, tools, and equipment.
Performing additional mechanical assembly, installation, and maintenance tasks as required.
Responsibilities
Montreal, Quebec, Canada
Space Concordia
Mechanical Team Member
Mar 2021 — Apr 2022 . 1 yr 6 mos
Involvement in developing the Rover for the university rover competition, in particular contributing to modifying the Rover wheel assembly’s design. (Solidwork)
The motor entirely protected and simple to take apart without removing the entire wheel assembly.
Responsibilities
Montreal, Quebec, Canada
CAD CAM GURU
Mechanical Design Trainee
Oct 2019 — Dec 2020 . 1 yr 2 mos
• Trained in mechanical software including ZW CAD+, AutoCAD, CATIA, PTC Creo, SolidWorks, and Ansys, with a focus on industry-specific domain expertise.
Hands-on involvement in real-time projects, including 3D modeling, drafting, and GDandT for Automotive components, Die and cope, Compressor casing, Jig and fixtures, and plastic components.
CAD projects- Swing Casting, ’Saniring- The ring Sanitizer’ and ’Multifunctional School Bag’
Responsibilities
Pune, India
Concordia University
Master of Engineering - M.Eng.
Mechanical Engieering
Jan 2021 — Jan 2023
Relevant coursework: CAMD, Aerodynamics, Aircraft Hydro Mech Fuel Systems, Tribology, etc.
CAMD Project- Modeled, assembled, and simulated the "Helicopter Rotor System" using CATIA V5.
Tribology Project- 3D modeling and analysis of shark skin denticle-inspired coating for the maritime vessel that reduces drag using PTC Creo and Ansys WB
Seminar Project- Design and Analysis of Whale fin inspired Turbine blade using Solidworks and Ansys WB.
Fluid Mechanics- Working on the computational study of time-dependent flow around a two-dimensional 2-cylinder and 3-cylinder tandem as a part of the Coursework Project.
Gas dynamics- Working on CFD simulation of the converging-diverging nozzle to recreate subsonic chocked flow and Supersonic flow using Ansys Fluent
Activities and societies: Space Concordia Robotics DivisionActivities and societies: Space Concordia Robotics Division
Major in Thermofluide Engineering.
Montreal, Quebec, Canada
Education
Pune University
Bachelor of Engineering - B.Eng.
Mechanical Engieering
July 2013 — July 2017
Top student in a class of 400.
Subjects such as Fluid Mechanics, Thermodynamics, Turbomachinery, Refrigeration, and Air Conditioning cleared with distinction
Bachelor's Project- Designed and developed multipurpose agricultural equipment to perform plowing, weeding, sowing, and spraying with minimal cost, weight, and size, and to be easy to use
Major in Mechanical Design Engineering.
Maharashtra, India
