Satish Mallya — Engineer & Maker

About

Engineer by trade, builder at heart.

I've worn about three engineering hats — mechanical first (JNTU), then industrial & systems (Georgia Tech). Most of my career has gone into making complex physical systems, like warehouses and production lines, predictable through simulation and data; building tools for those simulations quietly turned it into a software job too.

The electronics are older than all that — small DC circuits from taking toys apart as a kid, no manual, plus high-voltage AC work at Siemens (technically LV and MV). These days it's ESP32s in 3D-printed enclosures.

Since June 2025 the other half of my life has been just as full: a garage workshop with 3D printers, a laser cutter, a CNC router, and things I design on the computer and build by hand — shop tools that make everything else faster, a lithophane of a baby, one small product line.

The through-line is the same in all of it: take an idea, work out how it actually works, then make it real.

Discrete-Event SimulationWarehouse AutomationThroughput & Material FlowData AnalysisGenerative AI / LLM SystemsPythonC#AutoMod (expert)Excel + VBA3D PrintingLaser / CNC CuttingElectronics · DC to MV ACCAD & Mechanical Design

Engineering & Simulation

Making physical systems predictable.

Discrete-event simulation, warehouse automation and data analysis across logistics and manufacturing. The pattern that kept repeating — and quietly became half the job — was this: when a process is worth understanding, it's worth building a tool for.

Conveyor collision simulator

A standalone conveyor simulation module with collision detection, written in Python — built to reason about line behaviour outside the main model.

AutoMod scenario pipeline

Tools that auto-generate simulation scenarios, apply them to AutoMod models, run them and produce reports — while managing processor and memory usage across many runs.

3D cubing algorithm

A custom 3D bin-packing / cubing algorithm for tote sizing — turning a pile of items into the smallest set of containers that actually fit.

HMI imagery automation

Automated generation of HMI graphics with FOSS tools at Dennis Group — cutting what took hours down to minutes, and keeping it repeatable.

Line-downtime tablet app

A tablet-deployable data-collection tool for line downtime with instant reporting — capturing the right numbers on the floor, in real time.

Little's Law estimator

A tool to evaluate Little's Law for in-transit material estimation — a quick, defensible way to size WIP between stages.

Experience

2020 — Present
Operations Research EngineerDematic Global · Atlanta GA / Waterloo ON
2018 — 2020
Simulation EngineerDematic NA · Atlanta GA
2015 — 2018
Simulation EngineerDennis Group · Atlanta GA
2008 — 2010
Design Engineer / Type-Testing Lab SupervisorSiemens India · Mumbai, IN

Education

M.S., Industrial EngineeringGeorgia Institute of Technology · 2013
B.Tech, Mechanical EngineeringJNTU · 2007

That Siemens stretch is where the electrical side came from — localizing transmission equipment and running a type-testing lab (thermal, impulse, high-voltage AC — technically LV and MV — mechanical, water-ingress). It's also the origin of the "design it, then prove it works" habit.

Flagship software

Atlas — a local AI work engine.

A self-built "work engine" that runs entirely on two local GPUs. You hand a permanent Chief of Staff a piece of work; it plans the work into tasks in Atlas (an owned task tracker), executes each task through worker and independent reviewer agents on local models, delivers the result — and waits for your acceptance before moving on.

Ownergives work + accepts

Chief of Staffplans into tasks

Worker ⇄ Reviewerlocal LLMs, per task

Atlas trackertickets · reviews · spend

＋ an independent Supervisor process holds a reserved model slot so it can monitor, report and — if needed — wind down or restart the harness without being taken down with it.

Local-only models. A single llama.cpp server sized to the GPU room (e.g. Qwen3 27B); every model request is numbered and tracked as spend — no cloud, no surprises.
Worker + independent reviewer on every task, with owner-acceptance gates before anything counts as delivered.
A self-modifying "IT" that ships its own changes to the engine as commits — but only after your sign-off.
Atlas web UI for projects, tickets, reviews, performance and archives (Fastify + SQLite + React).
Boring on purpose: the harness is Python standard-library-only (tkinter), and the whole system is documented end-to-end.

Atlas owner dashboard showing engine status, tasks by state, dispatch and supervisor controls — Owner dashboard — engine status, tasks by state, dispatch & supervisor controls.

Conversations panel for messaging the Chief with live tool activity and interrupts — Talking to the Chief — live tool activity, interrupts, image attach.

The Bench

Maker & fabrication.

Since June 2025. A garage full of machines and a backlog of ideas — most of it STLs, renders and photos from the shop.

Lithophanes & light

One photo in, a lamp out. Custom lithophane panels that turn pictures into warm, glowing art — printed, framed and lit.

Ea-Nasir copper ingots lithophane — Ea-Nasir, est. 1729 BC

The shop

Where it all gets made: FDM printers (including a large-format Kobra 2 Max), laser cutter, CNC router — and a bench that's always mid-project.

Workbench with 3D printers and tools — The main bench

Pegboard tool wall in the workshop — Pegboard & small work light

Long LED shop lights mounted to the garage ceiling — Big shop light, installed

Workshop floor with large-format 3D printer and compressor — Kobra 2 Max & the floor

Shop tools & organization

If I do something more than twice, I build a tool for it.

Pegboard-mounted 3D-printed tool organization system — Cutter & bit organizer

Black 3D-printed curved plant pot held in hand — Printed planter

Laser-cut glowing letter W sign on wood — Glow sign sample

Original content

OC — designed from scratch, no outside reference. Each one started as a problem in the shop or at home and ended up on the printer; the renders below are straight from the CAD files.

Studio render of an original wind turbine blade design — Wind turbine blade

Peristaltic pump body and rotor rendered from CAD — Peristaltic pump — body & rotor

ESP32 relay enclosure render — ESP32 relay box

Screen printing press body render — Screen printer

Panel saw clamp parts render — Panel saw clamp

Lemon squeezer body render — Lemon squeezer

3D printer spool weight render — Spool weight

Arch lamp parts kit render — Arch lamp — parts kit

Printed ball bearing parts render — Printed ball bearing

Mini straight edge render — Mini straight edge

…and more in the library

The rest of the backlog — jigs, holders and one-offs still waiting for photos.

Laser RotaryCollet HolderDrawer BearingLithophane HolderTurn BoxShower HolderDiamond-Plate HolderControl-Box PartsAviation Plug JigCorner CapRings

Product

SharpCraft.

A knife-sharpening system I designed and build in the shop. A 3D-printed guide holds diamond or ruby rods at a precise, repeatable angle — 15°, 17° or 20° — so an edge comes out consistent every pass. Red and white rod sets; each unit is printed, assembled and tested by hand.

SharpCraft 20 degree sharpener with rods raised — 20° — rods up

CAD render of the SharpCraft sharpener body — In CAD, before print

Diamond sharpening stone setup with a folding knife — Diamond-stone stage

SharpCraft sharpener held in hand for scale — In the hand

SharpCraft guide with two rods at an angle — Rods seated

Modeled in CAD, printed on the Kobra, tuned at the bench — then it sharpens knives.

Contact

Get in touch.

Open to simulation & automation consulting, and to interesting maker / product collaborations. If you have a warehouse that needs modeling — or an idea that needs building — say hi.

satish.mallya@gmail.com Toronto / Waterloo, Ontario, Canada