Summary
Overview
Work History
Education
Projects Academic Experience
Technical Skills
Timeline
Generic

Varad Sonar

Rochester,NY

Summary

Use learnings from Packaging Engineering in combination with Mechanical Engineering to design appealing package, packaging systems for cost effective distribution in addition to save natural and organizational resources. I believe this will make me and my organization successful!

Overview

3
3
years of professional experience

Work History

Product Application & Development (Intern)

Anvit Laminators Pvt, Ltd
Thane, India
10.2023 - 06.2024
  • Collaborated with sales team and Dutch tool manufacturer to design thermoformed punnet. Assisted in optimizing product design using reference samples. Supported tool installation on the floor with Dutch installation engineer.
  • Collaborated with floor team, sales team, and tool designer to enhance product development and commercialization efforts.

Production and Quality (Intern)

Rajshree Polypack, Ltd
Daman, India
06.2022 - 07.2022
  • Executed testing protocols for PET, PP, PS and Barrier trays for weight, wall thickness and material distribution for repeatability and consistency.
  • Together with Production Supervisor optimized thermoforming machine parameters (temperature, vacuum and cycle time) resulting in reduction in rejection rates.
  • Barrier Packaging Container Company

Assembly Intern (Shopfloor)

3-Tek Engineering
Thane, India
05.2021 - 06.2021
  • Facilitated assembly and automation of packaging machinery, including pouch wrap and flow wrap systems.

Education

Master of Science - Packaging Science

Rochester Institute of Technology
Rochester, NY
12-2025

B.Eng - Mechanical

A P Shah Institute Of Technology
Thane, India
05-2023

Projects Academic Experience

  • PETg Medical Implant Tray Design, Ongoing, Designing and developing PETg medical implant trays for an Indian startup, focusing on structural integrity, material selection, and manufacturability.
  • Capstone Project, 08/01/25, 12/31/25, Developed PLA/TPS/PBAT thermoformed packaging as an alternative to polypropylene, evaluating material performance, sustainability and manufacturability. Developed functional prototypes highlighting material performance and visual finish.
  • Industrial Project - TE Connectivity, 01/01/25, 05/31/25, Converted traditional injection molded Tray to Sustainable Thermoformed Filled PP Tray. Designed and simulated tray models for drop tests using SolidWorks, ensuring structural integrity under handling conditions. Secured third place globally, winning $10,000 prize for the team.
  • Perfume Folding Carton Design, 08/01/24, 12/31/24, Designed a folding carton using ArtiosCAD with an innovative center-slide opening mechanism to enhance user experience. Produced detailed technical drawings and prototypes for evaluation.
  • Supply Chain & Distribution Design Project, 08/01/24, 12/31/24, Developed a complete packaging and supply chain system for a Xerox cartridge. Designed folding cartons and inserts using ArtiosCAD; optimized load configuration using TOPS Pro for enhanced space utilization. Validated packaging performance under ISTA-3A test guidelines to ensure supply chain durability.

Technical Skills

SolidWorks (Advanced 3D Modeling & 2D Drafting), AutoCAD, Autodesk Inventor, ANSYS (Finite Element Analysis), ArtiosCAD, TOPS Pro, Structural packaging design, corrugated packaging design, package design optimization, CAD-based packaging development, Thermoforming (PP, PET, PS), extrusion processes, tooling & mold installation, packaging testing (ISTA standards), product development, material selection, manufacturing feasibility analysis, MS Word, Excel, PowerPoint

Timeline

Product Application & Development (Intern)

Anvit Laminators Pvt, Ltd
10.2023 - 06.2024

Production and Quality (Intern)

Rajshree Polypack, Ltd
06.2022 - 07.2022

Assembly Intern (Shopfloor)

3-Tek Engineering
05.2021 - 06.2021

B.Eng - Mechanical

A P Shah Institute Of Technology

Master of Science - Packaging Science

Rochester Institute of Technology

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Varad Sonar