In the ever-evolving field of mechanical design, innovation is the driving force behind efficiency and cost reduction. Few embody this principle as effectively as mechanical design specialist Keval Babu, whose pioneering work in cost optimisation has garnered significant attention, particularly in the renewable energy sector.

“Mechanical design plays a critical role in cost reduction,” Keval explains. “By optimising components without compromising performance, we can significantly cut manufacturing expenses and improve overall efficiency.” His recent success in executing a design-centric cost reduction strategy for high-density polyethylene (HDPE) packaging components used in solar modules has set a new industry standard.

Keval’s approach balanced design productivity with cost-effectiveness, ensuring that the packaging components met all functional and engineering requirements while reducing production costs. “One of the most exciting aspects of this project was proving that a well-executed design strategy could directly impact profitability,” he notes. His achievement stands out as one of the first successful applications of such a strategy within the renewable energy sector.

The impact of Keval’s contribution was evident—his organisation saw a substantial increase in the profit margins of its newly developed solar module product. “It was rewarding to see how mechanical design could drive financial outcomes,” he says. What made his accomplishment even more remarkable was his role as a young engineer leading an initiative typically undertaken by seasoned professionals. “This project reinforced my belief that young engineers can bring fresh perspectives and technical knowledge to redefine products and processes.”

Undertaking this challenge, however, was not without obstacles. Keval had to quickly familiarise himself with advanced CAD (Computer-Aided Design) and FEA (Finite Element Analysis) software to conduct a thorough analysis of the new packaging component. “It was a steep learning curve,” he recalls. “Within a few weeks, I had to study ASTM standards and master Geometric Dimensioning & Tolerancing (Y145 2009).” Despite these challenges, his determination and technical acumen allowed him to successfully deliver a cost-effective and high-performance solution.

Central to his success was his deep understanding of injection molding principles. “Injection molding is a widely used process for producing plastic components efficiently,” he explains. “By optimising cycle time—especially during the cooling phase, which accounts for over half of the process—we improved efficiency without sacrificing quality.” By adhering to DIN 16901 tolerancing guidelines, Keval ensured that the molded parts met stringent quality and dimensional accuracy standards.

Beyond technical achievements, this project provided valuable learning experiences. His proficiency in SolidWorks improved significantly, and he refined his ability to communicate complex engineering concepts through multiple design presentations. A pivotal moment came when an ASTM test failure forced him to rethink his approach. “That setback pushed me to think critically and devise innovative solutions,” he shares. “It reinforced the importance of adaptability and resilience in engineering.”

Keval’s innovation in mechanical design exemplifies how meticulous engineering analysis and an inventive mindset can drive substantial cost savings. “As the industry embraces design-driven efficiency improvements, young engineers have an opportunity to make a real impact,” he says. His success story serves as an inspiration for aspiring professionals eager to contribute to the fields of cost optimisation and mechanical design.

“The key is to keep learning and pushing boundaries,” Keval concludes. “That’s where real innovation happens.”