Prshanth

Solving complex design challenges through data, technology, and 12 years of engineering experience.

Experience Summary

My name is Prashanth. I am a Mechanical Designer with over 12 years of experience solving complex engineering challenges and helping clients deliver high-performance, production-ready designs. Specialized in SolidWorks, I have designed and delivered mechanical systems and transformer assemblies for clients across 🇩🇪 Germany, 🇦🇺 Australia, 🇯🇵 Japan, 🇮🇳 India, 🇦🇪 UAE, 🇶🇦 Qatar, and several 🌍 African regions.

I have worked with renowned companies in Sri Lanka, supporting industries including energy (transformers), heavy machinery, shipbuilding, fuel systems, cement and grain storage, transportation solutions, and harbor machinery repair. My designs have helped clients improve manufacturing efficiency, reduce costs, and accelerate delivery timelines.

As a CSWP-certified SolidWorks specialist, I am skilled in Weldments, Sheet Metal, and Drawing Tools, producing IEC- and ISO-compliant 3D models and documentation. I manage projects from concept to production, collaborating with cross-functional teams to ensure precision, quality, and on-time execution.

Beyond design, I specialize in CAD automation, developing DriveWorks configurators and C#-based automation tools that have reduced engineering workload by up to 90%. I integrate VBA, Google Apps Script, and SAP to automate BOMs, cost sheets, and data pipelines, connecting engineering with real-time production and supply-chain systems. My focus is on creating intelligent, repeatable digital processes that make engineering efficient, accurate, and scalable.

Looking ahead, I aim to bridge mechanical engineering with software development, driving Industry 4.0 innovation through smart, automated design ecosystems. I hold a Diploma in IT and am currently pursuing a Bachelor’s in Information Technology at the University of Moratuwa (expected 2025).

I am fluent in C#, VBA, JavaScript, SQL, and Google Apps Script.

I built this website to showcase projects that are difficult to explain verbally, demonstrating how I combine engineering precision with digital problem-solving to deliver smarter, scalable solutions.

Recent Projects

Showcasing advanced SolidWorks design, precision modeling, and real-world problem-solving.

Advanced sheet metal and weldments

This project showcases expertise in advanced sheet metal and weldment design, utilizing SolidWorks to create complex, high-precision fabrications. The scope involved engineering structural frames and enclosures, with a focus on manufacturability, cost-effectiveness, and structural integrity. Key responsibilities included creating detailed 3D models, developing flat patterns for CNC cutting, defining weldment cut-lists, and producing comprehensive fabrication drawings. The project highlights a deep understanding of material properties, welding techniques, and modern manufacturing processes to deliver robust and reliable mechanical solutions.

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Substation Australian Mining Project 30 Units 300kVA, 1000kVA, 2000kVA

Engineered a series of high-capacity containerized substations for a major Australian mining operation, delivering 30 units with power ratings of 300kVA, 1000kVA, and 2000kVA. The project involved the robust mechanical design and integration of heavy-duty switchgear and transformers to withstand harsh environmental conditions. Key responsibilities included structural integrity analysis, advanced thermal management, and optimizing equipment layouts for maintenance and operational safety within a containerized footprint.

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Container Solar Substation 20 units

Led the design and engineering of a compact, containerized electrical substation for mobile and rapid-deployment scenarios. This project, executed in Solidworks 2025, encompassed the complete integration of medium and low voltage switchgear, transformers, and sophisticated control systems within a standard 20ft container. Key responsibilities included structural frame design, equipment layout optimization, thermal management simulations, and the creation of a comprehensive documentation package for manufacturing and assembly. The resulting solution provided a turnkey power distribution system that significantly reduced on-site installation time.

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Pole mounted transformer 300 units export market.

Designed and oversaw the production of 300 pole-mounted transformers for the international export market. This large-scale project involved optimizing the mechanical design for cost-effective manufacturing and ensuring compliance with various international standards. Key responsibilities included creating detailed 3D models and fabrication drawings in Solidworks, coordinating with suppliers, and implementing a quality control process to ensure each unit met stringent performance and durability requirements.

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Reverse Engineering - Bearing Housing

Executed reverse engineering projects to digitize and replicate legacy components for which no CAD data was available. Using a combination of 3D scanning and precision measurement tools, existing parts were meticulously analyzed to create accurate, manufacturable CAD models in Solidworks. This process also involved creating 3D printed prototypes to verify form, fit, and function before committing to final production.

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Special 5 point hanger to lift amorphous core

Designed a special 5-point hanger for lifting amorphous cores, ensuring safe and efficient handling during manufacturing and assembly processes. The design was validated through FEA to guarantee structural integrity under load.

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Reverse Engineering - CAT Rim

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Kitchen Countertop Design Europe Clients

Precision-engineered kitchen countertops for residential clients, translating on-site laser measurements into production-ready 3D models and fabrication drawings. This project involved coordinating with on-site technicians, integrating third-party components like sinks and faucets, and using specialized CAD software to ensure a perfect fit and finish. The result was a streamlined workflow from measurement to installation, ensuring high-quality, custom-fit countertops.

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Twistlock reverse engineering using ios lidar scan

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Sheet Metal Enclosure / Sheet Metal Fabrication

Designed and engineered a busbar chamber using advanced sheet metal techniques in Solidworks. The project focused on creating a durable, modular enclosure for high-current electrical busbars, emphasizing ease of assembly and maintenance. Responsibilities included developing precise flat patterns for fabrication, ensuring proper clearances, and producing detailed assembly drawings.

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Kaizen Cart

Designed and implemented a 'Kaizen Cart' to improve workshop organization and efficiency. This mobile tool cart was developed to support lean manufacturing principles by ensuring that tools and components are readily accessible, reducing waste, and improving workflow. The project involved 3D modeling in SolidWorks, sheet metal design, and creating fabrication drawings to bring the concept to life.

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Amorphous Core Transformer Development

Developed amorphous-core transformers in collaboration with Metglas Hitachi (Japan) to improve energy efficiency and sustainability. This project involved using FEA tools to optimize the design, reduce material costs, and enhance the transformer's performance. The work included creating detailed 3D models and fabrication drawings to ensure precise manufacturing and assembly.

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Design Automation Project Samples

Examples of design automation projects that transformed manual SolidWorks workflows into intelligent, rule-based systems—cutting design time, improving consistency, and enabling rapid customization across product families.