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Thamarai Kannan T.

Optical & Mechanical Design Engineer | Zemax, SolidWorks, Inventor | Ex-ASML EUV Systems

Coimbatore, India

Global rank:

17,995 / 144,324

Skill pts: 5

3D Modeling ANSYS API Autodesk Inventor Schematic Design

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About

Are you looking to bring a complex optical or opto-mechanical system from concept to a validated, working prototype? I can help you get there.

I hold an MSc in Photonics & Laser Technology (Leibniz University Hannover, Germany) and a BEng in Mechanical Engineering, plus 5+ years of hands-on experience spanning precision optical systems — including 3 years at ASML (Netherlands) performing calibration, qualification, and system-level troubleshooting on EUV lithography systems to strict optical and mechanical specifications. I've also worked in opto-mechanical R&D at Fraunhofer Institute and precision interferometer alignment at Max Planck Institute for Gravitational Physics.

My interdisciplinary background lets me balance optical performance, mechanical manufacturability, and cost — so what you get is a design that actually works when built, not just on paper.

Here's what I can deliver for your project:

• End-to-end system development — feasibility consultation, schematic design, BOM, and prototype validation
• Optical design & simulation — lens design, aberration correction, tolerance analysis (Zemax OpticStudio)
• Imaging systems — objectives, microscopes, relay systems, telescopes, projection systems
• Illumination optics — LED secondary optics, headlights, BLU systems, custom beam shaping
• Opto-mechanical design — kinematic & semi-kinematic mounting, athermalization, 3D modeling and structural/FEA analysis (Autodesk Inventor, SolidWorks, Pro/E, ANSYS)
• Precision alignment & metrology — interferometry, optical bench setup, calibration
• Signal processing & automation — MATLAB, Python
• Professional documentation — GD&T drawings, technical reports, LaTeX/MS Office

I bring the same discipline I used qualifying multi-million euro lithography systems to every project I take on — clear communication, rigorous documentation, and deliverables that meet spec the first time.

Let's discuss your project and how I can help you get there.

Experience

Optical & Mechanical Design Engineer Freelancer · Freelance Feb 2022 – Present 4 yrs 6 mos Coimbatore, TN, India - Designed and validated optical systems for microscopy and imaging applications based on customer requirements. - Developed illumination and imaging paths, optimized performance using Zemax simulations. - Designed opto-mechanical components using SolidWorks and AutoCAD with manufacturability in mind. - Selected optical components, prepared BOMs, and supported system assembly and debugging.
Optical relevance: End-to-end optical design ownership from concept to prototype.
EUV System Engineer ASML · Full-time Jan 2023 – May 2026 3 yrs 4 mos Veldhoven, NB, Netherlands - Calibrated, adjusted, and performance qualified EUV lithography systems against strict optical and system-level
specifications.
- Executed system-level troubleshooting using error codes,root-cause analysis, and structured escalation processes. - Conducted hands-on optical, mechanical, and system adjustments within ISO cleanroom environments.
- Supported new system introductions by identifying optical and process bottlenecks and proposing improvements.
- Logged optical performance, process data, and qualification results in SAP and technical databases, ensuring
traceability and quality compliance.
Optical relevance: High-precision system calibration, performance validation, cross-disciplinary troubleshooting, EUV
optics exposure, laser tracker, theodolite, Spatial Analyzer.
Optical Systems Intern Max Planck Institute for Gravitational Physics · Internship Oct 2018 – Apr 2026 7 yrs 6 mos Hanover, NDS, Germany - Commissioned, calibrated and validated a multi-interferometer optical measurement system with nano meter resolution
for satellite laser communication system application. - Diagnosed misalignments and damaged optical components across seven interferometers using various optical alignment
methods using lab equipments. - Designed precision opto-mechanical parts for realignment and integration using Zemax and Solidworks. - Validated system performance using photodiodes, oscilloscopes, and MATLAB-based signal processing.
Optical relevance: Interferometry, alignment, precision optics, metrology, Laser tracking, Theodolite, Spatial analysis.
Master Thesis/Research Intern–Optical Sensor Development Fraunhofer Institute for Production Technology · Internship Oct 2020 – Jul 2021 9 mos Aachen, NRW, Germany - Designed, developed, tested and validated a functional IR optical scanner with spectrometer for real-time monitoring of
additive manufacturing quality. - Designed and optimized optical layouts (illumination, projection, imaging) using Zemax. - Performed aberration correction using Zernike polynomials and finalized optical component selection. - Assembled an opto-mechatronic IR sensor and validated system performance through image and signal processing
in MATLAB.
Optical relevance: IR optics, sensor design, aberration theory, experimental validation, Laser tracking, Spatial analysis
Research Project–3D Optical DepthSensor Leibniz Universität · Internship Nov 2019 – Feb 2020 3 mos Hanover, NDS, Germany - Designed a 3D depth sensing system for smart warehouse applications. - Selected suitable 3D imaging principles based on literature review and system requirements. - Built an experimental prototype and processed 3D data using Python.
Optical relevance: 3D imaging principles, system prototyping, data processing.

Education

Leibniz University Hannover Master of science, Photonics and laser technology (Optical Technology) 2017 – 2021
Karpagam college of engineering Bachelor of Engineeering, Mechnaical Engineering 2011 – 2015

Licenses & Certifications

Product Design and Analysis CADD Centre Jan 2015 – Present