Santhakumar Sathiyan
Global rank:
2,067 / 35,658
Skill pts: 11


Passionate about solving engineering challenges and having multiple project work experience.

3D Models


  • Formula SAE Engineer Arizona State University · Dec 2017 – Jun 2019 1 yrs 6 mos Tempe, AZ, USA ● Optimized frontal area and angle of attack of wing elements and body panels to create low drag and enhance down force capabilities using CFD virtual wind tunnel flow analysis.
    ● Reduced part count using interchangeable parts and simplified component design for ease of manufacturing.
    ● Serviceability of parts are ensured by modular designs.
    ● Evaluated Epoxy bond strength and bilateral strength of carbon fiber composites.
    ● Performed Geometric Dimensioning and Tolerancing (GD&T) for assembly parts, closure systems and body panels.
    ● Performed surface and solid modelling of vehicle nose cone, side pods, rear wing, under tray and front wing.
    ● Designed and fabricated molds with Polyurethane Form and body panels with fiberglass and carbon fiber composite.
  • Mechanical Engineer Sembcorp Energy India Limited · Sep 2015 – Jul 2017 1 yrs 10 mos Nellore, Andhra Pradesh, India ● Member of multi-discipline Engineering team responsible for development of Capital Equipment and sub-systems.
    ● Decision making on product development, material selection, manufacturing processes and product documentation.
    ● CAE analysis – Static piping analysis, Nonlinear thermal deformation analysis, Nonlinear contact analysis on concentric pipes with CTE mismatch, buckling analysis of pressurized tubes with its supports.
    ● Stress concentration and Fatigue analysis on pressure vessels’ supports, extraction points, joints.
    ● Collaborated with manufactures to determine approach to manufacturing, setting tolerance and fits, surface properties, pre & post heat treatment and quality control procedures.
    ● Stress/Strain calculations, Moment of Inertia calculations and Factor of Safety considerations.
    ● Analysis of bending stresses, deflection and buckling of frames, beams and supports.
    ● Design and Analysis of high pressure tube coupling, strength of rivet & compound weld, and failure analysis.
  • Mechanical Engineer – Trainee NLC India Limited · Aug 2014 – Aug 2015 1 yrs Neyveli T.S, Tamil Nadu, India ● Developed a hydraulic piston jack assembly to test boiler drum safety valve.
    ● Designed hydraulic schematics, validated the operation characteristics and prepared detailed schematics drawing.
    ● Performed prototype testing to ensure operation of Non-return type air breather valve, PLC control over solenoid and interlocks.
    ● Performed Hydraulic Test by closing the recirculation valve to raise pressure up to 1.5 times the operating pressure.
    ● Conducted Hydraulic flushing operation with 2-micron filter until oil quality attains contaminants level not more than 10-microns.


  • Arizona State University Master of Science - Mechanical Engineering, Mechanical Engineering, 3.2 2017 – 2019 Activities and Societies: Formula SAE
  • Anna University , Chennai Bachelor of Engineering, Mechanical Engineering, 3.1 2009 – 2013 Activities and Societies: BAJA SAE

Other experience

  • CFD Analysis Stratification of Solar Storage Tank incorporated with Phase Change Material (PCM) ● Thermal analysis to analyze the heat storage capacity and heat transfer rate from PCM
    ● Topology optimized stratifier header design to acquire stratification layers with wide temperature gradients.
    ● Achieved enhanced stratification performance by incorporating Phase Change Material.
  • Investigating the Thermo-Mechanical Stresses in Flexible Electronics due to Coefficient of Thermal Expansion (CTE) Mismatch using ANSYS Simulation ● Performed contact analysis to investigate the stress concentration at Die – Solder composite interface and Solder composite – Substrate interface
    ● Conducted Thermal Cyclic loading simulation to study the behavior of different materials under varying temperature.
    ● Experimentally determined the strength of various polymer composites using Micro Tensile Testing Machine.

Licenses & Certifications

  • Certified SolidWorks Professional (CSWP) Dassault Systemes Jul 2019 – Present See credential
  • Engineer in Training (EIT) NCEES - National Council of Examiners for Engineering and Surveying May 2019 – Present See credential