Dev Shah — portfolio

About

I’m a product design engineer at Amazon in San Francisco, working on consumer hardware — ambient AI wearables and Ring and Blink security cameras and doorbells. I take products from concept through to mass production: the mechanical architecture, integrating RF, optics, PCBA, thermal and battery into an industrial design, and then the unglamorous part that decides whether a product actually ships — tolerance stacks, DFM, and EVT and DVT builds on the floor at contract manufacturers in Asia.

Before this I spent two years designing drug delivery devices in India, and started a 3D printing company that served dental clinics. Those projects are documented in full in the work section — they are where I learned to design mechanisms that have to work the first time.

Enthusiastic about design, cars, martial arts and chess.

Experience

Jan 2024 –

Product Design Engineer

Amazon, San Francisco
  • Lead and first product design engineer at Bee.computer, an ambient AI wearable startup acquired by Amazon.
  • Lead product design engineer for 2K and 4K Ring and Blink smart home security cameras and doorbells, shipping at over 10 million units.
  • Drove integration across RF, optics, PCBA, thermal, battery and industrial design.
  • Applied DFM and DFA, GD&T and statistical tolerance analysis to hit quality targets at speed.
  • Conducted FEA on critical features and sub-systems to converge on robust margins.
  • Supported EVT and DVT at contract manufacturers in Vietnam, Malaysia and China.
Jul 2023 – Dec 2023

Hardware Development Engineer Co-op

Amazon Robotics, Boston
  • Designed novel centre-of-gravity test equipment to optimise robot stability and manoeuvrability.
  • Automated image quality test stations for 2D and 3D cameras, cutting test time from 300 s to 30 s.
Feb 2020 – Jul 2022

R&D Team Lead — Mechanical Engineer

Mediscient Devices Pvt. Ltd., India
  • Developed a patent-pending wearable insulin injector with a bill of materials under $10.
  • Built a needle-safe autoinjector for high-viscosity drugs; led a team of 7 as the first full-time hire.

See the devices →

Apr 2020 – Jun 2022

Founder & Technical Lead

Beyond2D, India
  • Built a biocompatible 3D printing and 3D scanning facility for dental applications, delivering to more than 20 clinics; exited with 900% ROI.

Education

Sep 2022 – Dec 2023

MS, Mechanical Engineering + MicroMBA

University of California, San Diego
  • GPA 3.93/4.00.
  • Graduate researcher, Poulikakos Lab: nature-inspired 3D nano-metasurfaces with sub-50 nm features. Paper: 3D-architected gratings for polarization-sensitive structural color.
  • Teaching assistant: MAE156A Mechanical Design I, and MAE180A Spacecraft Design.
Jun 2017 – May 2021

B.Tech, Mechanical Engineering

Pandit Deendayal Energy University, India
  • GPA 9/10.
Issued Aug 2024

Project Management Professional (PMP)®

Project Management Institute

Skills

Product design
DFM and DFA, GD&T (ASME Y14.5), statistical tolerance stacks, FEA, failure analysis and root cause, build reports, supplier interface, EVT and DVT
Camera systems
Optics integration (lens and sensor stack), camera module packaging, thermal interfaces, stray light and baffling, sealing and IP rating for outdoor use
Manufacturing
Injection moulding, die casting, stamping, CNC, ultrasonic welding, adhesives, gasketing, O-rings, snaps and bosses, thread forming, design for assembly
Tooling and quality
Contract manufacturers in Vietnam, Malaysia and China; process capability and CPK
CAD and simulation
Siemens NX, SolidWorks, Fusion 360, Ansys, COMSOL, Star-CCM+, Adams
Programming
Python, MATLAB
Languages
English, Hindi, Gujarati

Earlier research

2021 – 2022

Microneedle patch platform

Beyond2D LLP, Vadodara
  • Hollow 3D printed microneedles to replace the indwelling needles in commercial wearable injectors. Top 10 innovation award, National Manipal BioTech Hackathon 2021.

Microneedle platform →

Jul 2019 – Dec 2020

Compliant surgical tools

ORSP, PDPU
  • Compliant joints in a surgical gripper made of biocompatible plastics or Nitinol, eliminating multi-part assemblies for towel clamps, sponge forceps and tube clamps.
  • Received ₹1,25,287 in funding from the Office of Research and Sponsored Projects, PDPU. Patent filed Dec 2020.
Jan 2020 – Apr 2020

Covid-19 outbreak modelling

PDPU, Gandhinagar
  • Modified SEIR model of the outbreak in India across six lockdown strategies. Published in IJSREM, Volume 04, Issue 04.

Covid-19 analytics →

Feb 2018 – Jan 2021

ATV Research Group — Head of Design

PDPU, Gandhinagar
  • Head of design for a combustion ATV, then structural and thermal design lead for an electric one, for BAJA and e-BAJA SAE India.
  • Came first in the Virtual Design Round among 350 teams from across India.

ATV research group →

Beyond engineering

May 2018 – Jun 2018

Mathematics teacher

Lion’s Blind Girls’ School
  • Devised innovative methods to teach maths to young blind children.
  • Made the permanent teachers more comfortable with computers and tablets so they could keep using them for teaching after my internship finished.
2010 – 2015

National karate champion

Black belt
  • Represented India in the South Asia Karate Championship and came third.
  • Won several national, state and district karate tournaments.