Available for new opportunities

Hi, I'm Gaurav Baglekar.

Engineering Manager & System Integration Expert

I specialize in robust mechanical design, EV charging infrastructure, and precision robotic systems. With over 5,000 hours of CAD experience and a passion for thermal dynamics, I bring complex hardware concepts to mass-production reality.

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About Me

Bangalore, India
B.E. (Hons.) Mechanical, BITS Pilani
gaurav.baglekar@gmail.com

I am a highly driven Mechanical Engineering Manager and System Integration Expert with a proven track record in the Electric Vehicle (EV) and Defense sectors. With over 5,000+ hours of advanced CAD experience in Solidworks, I specialize in transforming conceptual designs into mass-produced, robust physical products.

My expertise spans across designing 15-minute fast-charging infrastructures, developing IP/IK-rated active and passive thermal management enclosures, and engineering high-precision inertially stabilized robotic systems for aerospace and military applications. I excel in cross-functional team leadership, rapid prototyping, and executing rigorous GD&T standards to ensure unparalleled manufacturing quality.

Work Experience

System Integration

April 2022 - Present
Exponent Energy
  • Responsible for integration of Battery-Charger-Connector with 15mins fast charge cycle (4C rate).
  • Defined system specifications for the revolutionary 15mins fast charging system.
  • Spearheaded connector development to enable efficient and safe fast charging.

Engineering Manager

April 2020 - April 2022
Ola Electric Mobility
  • Led the design and production of injection molded plastic parts and thermal solutions (active/passive) for outdoor charging.
  • Designed and developed IP and IK rated charging enclosures, portable chargers, and mass-produced bulk charging systems.
  • Developed automated parking & charging systems for 2W vehicles and managed a 6-member team of CAE, CFD, and Design experts.

Mechanical Design Engineer - Senior Member

Aug 2016 - March 2020
Tonbo Imaging
  • Designed compact robotic drives with precise motion control for inertially stabilized systems (Airborne, Sea, Land).
  • Ensured product compliance with MIL 810G, JS55555 standards, Aerospace standards, and IP ratings up to IP67.
  • Designed lightweight UAV Gimbals (<1Kg) and heavy-duty Motion Simulator platforms (350kgs).

Core Skills & Expertise

CAD & Design

Solidworks (5000+ hrs) PTC Creo 2.0 Autodesk Inventor Catia AutoCAD GD&T Tolerance Stack-up

Simulation & Management

Solidworks Simulation Ansys Workbench Simsolid Thermal Analysis Structural Loading PLM PDM Tools

Manufacturing

Injection Molding Sheet Metal Fabrication 3D Printing Laser Cutting CNC Machining Rapid Prototyping Assembly Testing

Key Projects & Achievements

Formula Category Vehicle Design

SUPRA SAE India 2014

Worked in a 25-member team to design, analyze, and fabricate manufacturing components, chassis, and the braking system of a Formula type race car. Secured overall 23rd rank out of 210 teams nationally.

Human & Electric Powered Vehicle

SAE Efficycle 2014

Designed, analyzed, and fabricated the chassis and suspension system in an 8-member team. Presented the vehicle at the National level competition and secured 58th rank among 263 teams.

Volvo Camshaft Machining Automation

MAHLE Engine Components (Internship)

Designed an automation system for the complete Volvo camshaft machining line. The system design was highly appreciated, accepted, and forwarded to higher authorities for full implementation.

Select Achievements

  • Secured 1st rank in design and fabrication of an automated pole climbing robot and RC Car event (IIT Mandi).
  • Secured 1st rank in CAD design competition organized by CTE BITS Goa (designed an F1 car).
  • Design Judge for Formula Bharat (January 2020).
  • President, Mechanical Engineering Student Association, BITS Pilani Goa Campus.

Engineering Insights (Blog)

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