Welcome !
I'm Nalaka
Engineering with precision, powered by purpose. I create innovative solutions that perform, and efficient systems that last. This portfolio reflects sharp Design, Automation and Mechanical Engineering experiences, and a simple belief: "Engineering doesn’t just fix — It transforms, Drives progress, and Builds what’s next."
about me
I was born in Sri Lanka and moved to the United States in 2007, driven by a desire to grow, challenge myself, and build a future through engineering. While working full-time, I earned a BSc in Mechatronics Engineering—where I found my passion for combining mechanics, electronics, and intelligent control systems.For over five years at Qunnet Inc., I applied these skills to real-world projects, designing mechanical systems, troubleshooting automation processes, and collaborating on solutions that bridged disciplines. That experience shaped my ability to think critically, adapt quickly, and engineer with purpose.I’m an engineer who thrives at the intersection of innovation, practicality, and purpose. With a strong background in mechanical and systems engineering, I specialize in designing solutions that not only solve technical problems but also deliver real-world impact. From developing precise CAD models and optimizing automation processes to integrating hardware with intelligent control systems, I bring both creativity and discipline to every stage of the engineering lifecycle.What drives me is more than just building things—it's building the right things. I care deeply about understanding the problem, the industry context, and the people affected by the solutions. My approach is rooted in continuous improvement, collaboration, and a commitment to excellence, whether working independently or within a cross-functional team.
My Skills
Mechanical Design Skills
• SolidWorks Mastery – Part modeling, assemblies, and 2D drawings including views, annotations, and BOMs using SolidWorks as the primary tool.
• Additional CAD Platforms – Experience with AutoCAD, CATIA V5, and Autodesk Inventor for design versatility.
• Parametric Modeling Expertise – Strong grasp of design intent, sketch relations, and feature-based modeling using extrude, revolve, sweep, and loft tools.
• Advanced Modeling Techniques – Proficient in surface modeling, sheet metal, weldments, and mold/tooling design.
• Complex Assembly Design – Skilled in multi-body parts, advanced mates (e.g., cam, gear), and in-context feature creation.
• Design Validation – SolidWorks Simulation experience for FEA, thermal and structural analysis, and motion studies.
• Assembly Optimization – Use of interference detection and collision checking to ensure functional and manufacturable designs.
• Design Automation – Familiar with Design Tables, custom macros, and DriveWorksXpress for configurable part families.
• PDM & File Control – Effective use of SolidWorks PDM and structured file management to maintain design integrity.
• Model Organization – Clean feature tree structures, naming conventions, and template usage to ensure clarity and consistency.
• Visualization & Communication – Creation of photorealistic renderings and animations using SolidWorks Visualize.
• Collaboration Tools – Familiarity with the 3DEXPERIENCE platform for design reviews, markups, and team collaboration.
• Mechanical Engineering Practices – Application of GD&T, tolerance stack-ups, and DFMA principles.
• Standards Compliance – Adherence to ASME, ISO, and ANSI engineering documentation and design standards.
Data Analysis, Simulation, Material Modeling Software & Tools
• MATLAB – Advanced numerical computing and modeling for dynamic systems, control analysis, and simulations.
• Python / PyQt5 – Scripting and GUI development for engineering automation and hardware control.
• AI Prompting – Using language models for creative engineering ideation, prototyping, and automation.
• Oriental Motor Sizing Tools – Calculate inertia, torque, speed vs load.
• Calc-Tool – Custom calculation sheets and logic-driven tools for fast mechanical or electrical validation.
• Ansys CFD – Fluid and thermal simulation for optimizing mechanical system performance.
• Thermo-Calc – Thermodynamic analysis for material phase behavior and alloy design.
• BIOVIA – Molecular and material simulation tools for research and product development.
Automation & Control Systems
• Galil DMC (Galil Tools / Galil Design Kit), Applied Motion SCL – Precision motion control programming for servo and stepper motor systems.
• Programming 6 axis robots (Mecademic MECA500) – introduce 6 axis robots for pick and place, and displacement.
• Integration Skills – Expertise in wiring diagrams, control panel setup, and integrating mechanical and electrical components.
• Safety measures – integrate safety systems such as emergency stop, light curtains, safety relays, and interlocks.
• Allen-Bradley PLC (Studio 5000 Logix Designer)– Programming and troubleshooting of industrial automation systems using ladder logic.
• HMI Development (Studio 5000 View Designer/ Red Lion with Crimson 3.0) – Designing intuitive operator interfaces for real-time monitoring and control of industrial equipment.
Embedded Systems & Electronics
• Microcontroller Programming (C/C++) – Developing embedded code for hardware control and sensor communication.
• Communication Protocols (GPIO, I2C) – Implementing digital I/O and peripheral communication in embedded systems.
• OrCAD PSpice / PSpice A/D – Circuit simulation and validation for analog/digital designs.
• Autodesk Eagle – Schematic capture and PCB layout design for custom electronics.
• LabVIEW – Visual programming for data acquisition, testing automation, and control system validation.
• Signal Testing Tools – Skilled in using oscilloscopes and signal generators for circuit diagnostics and prototyping.
Engineering Standards & Compliance
• Standards Familiarity – Working knowledge of ANSI, NEMA, UL, IEC, and IPC-A-600/610 standards for design and compliance.
• Documentation Compliance – Adherence to ISO 9001, ASME Y14, and industry-specific drawing and quality formats.
• Export Controls – Experience with HS/ECCN codes for international compliance and classification.
Quality Systems & Process Control
• DMAIC (Define, Measure, Analyze, Improve, and Control phases) – Applying structured methodology for continuous improvement and process optimization.
• FMEA (Failure Mode & Effects Analysis) – Identifying potential failure risks and implementing preventive measures.
• MSA (Measurement System Analysis) – Evaluating precision and accuracy of measurement tools and systems.
• SPC (Statistical Process Control) – Using statistical methods to monitor and control manufacturing quality.
• PPAP (Production Part Approval Process) – Automotive and aerospace process documentation for part qualification.
Project Management & Business Tools
• ROI Analysis – Assessing technical decisions based on return on investment and cost-benefit justification with performance tracking, financial feasibility studies, and cost control plans.
• Tableau – Creating dashboards and visual reports to communicate technical data and performance metrics.
• Asana – Managing projects, timelines, and collaboration across engineering and cross-functional teams.
education
I earned my BSc in Mechatronics Engineering from California State University - Chico.
The Mechatronics Engineering program at CSU Chico combines mechanical, electrical, and computer engineering to develop smart systems and automation. Emphasizing hands-on learning, it covers robotics, control systems, and embedded design. Students gain real-world experience and teamwork skills, preparing them for careers in advanced Mechanical, Manufacturing, Automation, and cutting-edge technology industries.
Mechatronics Engineering Classes
Fun University Projects
Shower Saver
Designed and developed an automated shower system to deposit cold water coming out of the shower in a tank and pumps back into the shower when desired set temperature reaches. The intention of the project is to eliminate the uncomfortable first bit of cold shower.
It was a great experience and a challenge to create a waterproof enclosure to protect electronics contacting water.
Here i learned to design PCBs for fabrication.
Battery Tester
Designed and automated test equipment for testing and separating batteries (Alkaline Size-C) based on their voltages. Batteries below 1.5V should separate and fall to the left and above 1.5V falls to the right. The test equipment should test no less than 20 batteries a minute with perfect repeatability.
When the battery is dropped through the tube, two actuator mechanisms press against anode and cathode measuring voltage twice. If voltage sensor reads the voltage at least once below 1.5V, the separating flap tilts to right and battery falls to the left side. When voltage above 1.5V, the separating flap tilts to left and battery falls to the right side separating the good vs bad batteries.
Achieved the test speed of 60 batteries a minute.
Beam Crawler
Built an motorized model vehicle to crawl up/down on a slanted (45°) surface without derailing and collect a 1g of mass with no less than 0.3 m/s speed, spending no more than 1 J of energy.
experience
I joined Meritec Inc. in August 2019 and spent over five years contributing to the design and development of high-performance electronic connectors and cable assemblies as well as automated production equipment. Meritec serves mission-critical industries such as Automated Test Equipment, Defense, Industrial, Medical, and Datacom with rugged, high-speed interconnect solutions. In 2023, Meritec became part of Qnnect Inc., a global interconnect platform that also includes PacAero, Hi-Rel, and Cristek. At Meritec, I was involved in the full product lifecycle—from concept and prototyping to testing and production—helping deliver reliable, application-specific solutions. My role required cross-functional collaboration with electrical engineers, quality teams, and manufacturing to meet strict industry standards. Working on products for environments requiring durability, signal integrity, and precision gave me a deep appreciation for advanced materials, shielding techniques, and design for manufacturability. This experience sharpened my design skills, broadened my understanding of mechanical / electrical systems, and reinforced the value of innovation in harsh and high-performance applications.
Here are some of my contributions for improving production capacity, quality and cost reduction.
Introduced this coax cable braid soldering process, reducing production time from 12 to 3 minutes and cutting operator count by 23. Achieved 30% cost savings and eliminated defects like melted dielectrics and excess solder, ensuring consistent high-quality assemblies. Most important thing i learned from this project is " some solutions come in simplest and inexpensive ways".
Video - Prototype Stage
To support a sixfold increase in production within a single year, I implemented automated manufacturing systems that scaled operations efficiently and sustainably. I worked closely with cross-functional teams—both internal and external engineers and technicians—to ensure seamless integration, optimize workflows, and maintain product quality throughout rapid expansion. Videos showcasing some of these systems can be found in the Projects section.
I contributed to the full product development lifecycle from concept to final validation, while maintaining detailed documentation in a PDM environment. My responsibilities included 3D part designing, prototyping, assembling, and inspecting mechanical components, building complete systems, and performing functional testing to ensure product reliability and performance. This hands-on involvement helped ensure design intent was carried through to production with accuracy and quality.
conducted root cause analysis by forming hypotheses, defining problems, and developing targeted test methods. I analyzed data to recommend effective solutions and collaborated with specialized labs to investigate material properties using techniques such as SEM imaging, X-ray analysis, TGA, and molecular composition testing. This multidisciplinary approach ensured deep insight into failures and supported data-driven engineering decisions.
Designed detailed 3D models of custom equipment and manufacturing fixtures tailored to specific production requirements. These models were created with precision to ensure both functionality and manufacturability. I also generated 2D technical drawings and Mastercam generated G-code files to support accurate CNC machining and fabrication. After machining, I conducted hands-on assembly of components, followed by inspection and validation to ensure all parts met dimensional and functional specifications. I performed thorough testing of the assembled equipment to evaluate its performance, durability, and operational capability. This process ensured high-quality builds and continuous feedback for design improvements, supporting efficient production workflows and robust engineering solutions.
Supported the outsourcing and launch of multiple international projects within six months, ensuring no loss in product quality or operational efficiency. I collaborated with Malaysian port authorities to verify regulatory compliance and worked closely with the overseas production team to establish manufacturing processes smoothly and on schedule. This effort demonstrated my ability to manage global operations while aligning technical, logistical, and regulatory elements effectively.
Participated in team efforts for analyzing cost estimations with presenting project costs, ROI calculations, cost-benefit comparisons, performance tracking, financial feasibility studies, and cost control plans.
Workshop Tool Skills
Precision Assembly Tools – Torque wrenches, hex/Allen tools, crimpers, and hand soldering equipmentFixture Setup & Alignment – Assembling and adjusting mechanical fixtures for testing or productionInspection Tools – Calipers, micrometers, height gauges, pin gauges, and go/no-go gaugesTorque Test Systems – Setup and operation of MARK-10 and other digital torque analyzersOscilloscopes & Multimeters – Signal diagnostics and electrical testingDrill Press & Bench Tools – Light fabrication and prototypingCable Prep Tools – Stripping, cutting, tinning, and coax cable preparation for assemblyCleanroom/ESD Protocols – Familiar with safe handling of sensitive electronics and assemblies
Soft Skills
Strong problem-solving and analytical thinkingEffective cross-functional collaborationClear technical documentation and communicationAdaptability to fast-paced environmentsHands-on and detail-oriented approachSelf-driven and eager to learn new toolsExperience leading or supporting automation projectsAbility to work across engineering, production, and compliance teamsProject ownership from concept to implementationGlobal collaboration and remote coordination experience
projects
Automated Resistance Welder
Designed and developed seven programmable resistance welders capable of spot welding 94 cables onto copper contacts within five minutes, with high repeatability and built-in fault detection that automatically halts and re-welds if parameters fall outside tolerance. This system integrated components including the Amada Miyachi HF-2500A high-frequency inverter, Dover XYRB motorized stage, Galil DMC-21x5 motion controller, Red Lion CR3000 HMI, and Keyence sensors. I programmed the motion controller using Galil Design Kit and configured the HMI interface with Crimson 3.0, enabling precise coordination and real-time monitoring across the system.
Connector Insertion 6-Axis Robot
Designed a custom mounting base and contact roll‑feeder interface to streamline part delivery. Though the mechanical design was minimal, integrating the Meca500 through Mecademic’s API (Application Programming Interface) using MecaPortal was an invaluable learning experience. I authored TCP/IP commands to coordinate motions, handled tool‑center communication, and assured reliable high‑speed placement. Working with such a precision micro‑robot taught me about footprint constraints, endpoint accuracy, and system agility. The result: a compact, efficient, plug‑and‑work automation cell that delivered consistency, scalability, and hands‑on expertise with advanced robotic programming.
Solder Dispenser Robot
Implemented Fisnar F4200N 3-axis benchtop robots to automate the precision dispensing of solder and flux paste. I designed custom fixtures and modified the setup to align with process requirements, enhancing control and accuracy. The system was integrated with a VC300 pneumatic valve controller, VDP150 positive displacement valves, and VMP30H poppet valves to achieve consistent and efficient material dispensing. This project improved repeatability, reduced waste, and gave me valuable experience in robotic automation and fluid control systems.
Automated Spot Solder Robot
I designed and automated four spot soldering robots for hot bar soldering tinned coax cables of various gauges to copper contacts with high repeatability. Each system performed precise engagement, soldering, cooling, disengagement, and indexed to the next location automatically. I integrated Amada Miyachi HF-2 inverters, Dover XYRB stages, STAC-6 SE drivers, Red Lion CR-3000 HMIs, and Keyence sensors. Programming was done using Applied Motion SCL and Crimson 3.0. I also collaborated with AIT to design custom hot bars tailored to specific cable geometries, ensuring consistent quality and performance.
Range of Motion Tester
Developed a custom test device to evaluate the circular range of motion and rotational integrity of cable assemblies. This system detects collision points and friction by measuring peak torque during rotation and automatically halts movement if torque exceeds a defined threshold. The setup included a Raspberry Pi controller, MARK-10 MR52-12 torque sensor, NEMA 23 PKP stepper motor, and integrated display. I programmed the microcontroller using Python and created a responsive HMI interface with PyQt5 for real-time monitoring and control. This project enhanced quality testing accuracy while helping to identify mechanical design flaws in rotating cable assemblies early in development.
Contact
I'm truly delighted and excited to hear from you! Feel free to reach out to me anytime through email, phone, or LinkedIn. I’d love to connect and have a conversation with you.
-- Nalaka --
Email: [email protected]
Phone: (530) 570 2694
Linkedin: www.linkedin.com/in/nalakagedara