Waqas Ali Shah

In my current role as Senior Mechanical Design & Manufacturing Engineer at Raythorne (Client: DG MATRIX, USA), I am leading the enclosure design, system packaging, and thermal management for 400 kW and 200 kW power routers. These advanced systems integrate energy from grid, solar, and battery sources for EV charging and high-capacity battery storage. My work involves:

Concept-to-production development: transforming requirements into manufacturable designs.

Rapid prototyping and testing of enclosures, heat sinks, and cooling systems.

Design-for-manufacturing (DFM) to optimize cost, performance, and scalability.

Coordination with suppliers and fabricators for precision parts (FR4 supports, liquid cooling blocks, busbars, and housings).

This project has strengthened my expertise in prototyping, manufacturing processes, and product realization, making me confident I can guide your idea smoothly from concept to production while ensuring efficiency and quality.

Implemented efficient workflow processes to enhance production quality and speed.

Optimized inventory management systems, reducing waste and improving cost efficiency.

Developed maintenance schedules for machinery, reducing downtime by 15%.

Coordinated workshop activities, ensuring that project deadlines were consistently met.

Facilitated training programs for technicians to improve skills and safety compliance.

Led process improvement initiatives that increased overall operational efficiency.

Managed and led a team of 350 technicians and inventory professionals, ensuring efficient operation of the workshop.

Pioneered the integration of new technologies to streamline workshop processes and enhance productivity.

Spearheaded quality assurance initiatives to maintain high standards in project execution and delivery