Khajani
Sivapala
Mechatronics Engineering
University of Waterloo
CURRENT POSITION
Tesla
Automation Engineering Intern
01 / EXPERIENCE
Experience
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Automation Engineering Intern
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- Developing first AI-integrated camera detection on 6 stations for foreign object debris (FOD), protecting $1.1M+ Megapack/escape.
- Designing good/bad sample validation trials confirming FOD exceeds the AI camera's 5-pixel resolution minimum.
- Designing, planning, and pitching a potential capital project investment, from CAD to senior engineering reviews.
Mechanical Lead
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- Leading mechanical design for a 32+ member team, running SolidWorks design reviews from concept to prototype.
- Optimized the quadcopter airframe for 18% higher strength-to-weight, with modular sub-assemblies for under 10 min field repairs.
- Redesigned motor arms over 5+ finite element analysis (FEA) iterations, cutting stress concentrations.
Robotics Engineer
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- Designed and modeled the quadcopter base and propellers in SolidWorks.
- Helped develop the electrical schematic for component and power connections.
- Created the full quadcopter assembly sketch integrating mechanical and electrical systems.
Engineering Analyst (Design & Automation)
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- Implemented a PLC scan-verification interlock to halt defect propagation, eliminating 30 min/vehicle of rework and ~$750K output risk per occurrence.
- Led failure analysis on a driveshaft press, isolating spring stiffness as the root cause and redesigning to cut faults by 70%.
- Redesigned the structure of a $25K, 36-unit pallet array from root cause findings, cutting repeat failures ~30%.
- Applied DFM/DFA to redesign a conveyor skate in SolidWorks, cutting removal time 70% with quick-release fastening.
Aerodynamics General Member
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- Developed a carbon fiber undertray, improving structural performance.
- Fabricated a 260" × 180" vacuum bag to enable consistent curing.
- Supported aerodynamic component testing and manufacturing prep.
Chassis General Member
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- Ran adhesive tests to optimize steel chassis bonding.
- Machined chassis components to tight tolerances.
- Processed 20+ steel tubes and assembled the chassis frame.
Maintenance Engineering Intern
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- Troubleshot recurring sensor faults on PLC-controlled equipment, cutting repeat failures ~20%.
- Engineered digital inventory tracking (CMMS) for 2,900+ parts, cutting retrieval time ~60% to speed repairs.
First Year Representative, Mechatronics Engineering
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- Advocated for Mechatronics students and helped improve course delivery.
- Analyzed student surveys, contributing to an improvement in class performance of about 30%.
Medical Administrative Assistant, Biomedical Engineering
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- Assisted BME technicians with diagnosing and repairing neonatal incubators.
- Uploaded 25+ equipment data sheets and edited floor plans to update the hospital database.
- Organized and proofread technical documents to improve accuracy.
02 / PROJECTS
Projects
Click any project to open its photos and videos.
Canadian Nuclear Laboratories Innovation Challenge (Feb 2026)
#1 Best ExecutionEmbedded SystemsSensor FusionIoTC++ FirmwareAlert Logic
Telligence: Hazard Detection
Integrated IMU, magnetometer, temperature/humidity, IR, and touch sensors into one hazard score, detecting 7/7 simulated hazards. A two-layer alert logic sends a 3 g+ crash to a critical LCD and buzzer warning in about 3 s. Non-blocking C++ firmware streams 8 channels every 5 s to off-site responders.
Photos & videos ↗ Code on GitHub
BiomechatronicsWearable SensingHMIArduinoServo ControlTendon-Driven
ReFlex: Teleoperated Robotic Hand
Independently built a teleoperated robotic hand with custom flex-sensor mapping that mirrors operator gestures at 90% accuracy and under 500 ms delay. Designed the servo-actuated, tendon-driven finger mechanism through 4+ iterative prototypes.
Photos & videos ↗ Code on GitHub
Toyota Motor Manufacturing Co-op (Jan – Apr 2026)
PLC Ladder LogicFail-Safe DesignInterlock LogicControl SystemsSensor & Barcode IntegrationRoot Cause Analysis
Toyota: Fail-Safe Quality Control
Engineered a fail-safe verification gate in the PLC logic so the process only advances once a barcode scan confirms the part, blocking wrong-part errors at the source. Eliminated 30 min/vehicle of rework and ~$750K of output risk per occurrence. Owned the hardware build: sourced parts, wired the full I/O block, and integrated the scanner, interface box, and pushbutton into one controller.
Photos & videos ↗
WATbotics Robotics Design Team (Jan 2026 – Present)
SolidWorksFEAModular DesignStructural OptimizationElectromechanical IntegrationPixhawk Flight Controller
Quadcopter: Modular Airframe Design
Mechanical lead on a quadcopter built from scratch. A modular airframe with separate arms and plates lets any sub-assembly be swapped in under 10 minutes, and 5+ FEA-informed iterations delivered an 18% strength-to-weight gain. Co-planned the wiring architecture around a Pixhawk flight controller, ESCs, GPS, and a telemetry link.
Photos & videos ↗
Assistive TechnologyRapid PrototypingMotion ControlLEGO EV3Encoder Feedback
DotMatic: Braille Printer
Developed a 3-axis assistive braille printer that converts text files to tactile braille for children, versus $2K+ commercial embossers. Achieved 95% dot depth and readability at 2.5 mm pitch using 1° encoder control and row-by-row printing.
Photos & videos ↗ Code on GitHub
Toyota Mechanical Innovation Challenge (May 2025)
Mechanical DesignSolidWorks3D PrintingDC Motors & ServosSensors
AGV Design
Designed an automated guided vehicle for dual-mode door and box transport with safe warehouse navigation. Modeled and 3D-printed custom grippers in SolidWorks, and built a lift system with Tetrix, DC motors, servos, a PS4 controller, and sensors.
Photos & videos ↗