Proficient in 3D modeling and mechanical design using SolidWorks, with additional experience in Autodesk Inventor, ANSYS SpaceClaim, and PTC Creo. Key design work includes:
Modeled tubular and embedded oscillating heat pipes (OHPs) for thermal management applications
Designed and assembled complete experimental test setups involving multi-component integration
Created custom heat exchangers, flanges, manifolds, and sealing interfaces for fluidic systems
Developed 2D fabrication-ready CAD drawings for manufacturing
Collaborated with machine shops for tolerance specification, part verification, and prototyping
Proficient in ANSYS Fluent, ANSYS Icepak, CFD meshing, and COMSOL Multiphysics. Key projects include:
Simulated fluid flow and mixing behavior in a mixing elbow using ANSYS Fluent, validating turbulence and velocity profiles
Conducted CFD analysis over a NACA 0012 airfoil of external flow using ANSYS Fluent, focusing on lift and drag coefficient
Modeled electrostatic forces and spray evolution of electrosprayed droplets using COMSOL Multiphysics, tracking particle dynamics and electric field interactions
Developed a design methodology for the prediction of thermal performance oscillating heat pipes (OHPs) using COMSOL Multiphysics
Extensive hands-on experience in cleanroom micro/nanofabrication processes involving photolithography, thin film deposition, etching, metrology, and substrate bonding. Proficient in operating a wide range of tools and systems:
Photolithography:
Mask design and fabrication using Heidelberg Instruments DWL 2000
Photoresist processing: spin coating, soft baking, exposure, and development
UV/DUV exposure tools:
SUSS MJB4 Contact Aligner
SUSS MA6-BA6 Contact Aligner
ABM Contact Aligner
Thin Film Deposition:
Co-sputtering of binary/ternary targets (e.g., Ti-Zr) using AJA sputtering system
Chemical Vapor Deposition (CVD): Oxford PECVD 100 for SiO₂ deposition
Etching & Cleaning Processes:
Dry etching:
Oxford 81/82 Etcher
ICP/RIE single chamber Bosch process
Unaxis 770 Deep Silicon Etcher
Resist stripping: Anatech resist strip system, YES EcoClean Asher
Wet etching & cleaning: KOH hood and bath, HF bath, MOS clean, general chemical cleaning
Metrology & Characterization:
P7 Profilometer, Filmetrics F50 Film Thickness Measurement
VCA Optima Goniometer for contact angle measurement
Microscopy tools:
AFM (Veeco ICON)
SEM with EDS
XRD for structural characterization
Additional Tools:
Micro drill, VersaLaser Engraver/Cutter, SUSS SB8e Substrate Bonder
Independently conceptualized, designed, and assembled custom thermal systems with minimal heat loss and integrated recirculating chillers, heaters, and vacuum pumps to evaluate the performance of thermal devices such as oscillating heat pipes (OHPs).
Extensive hands-on experience in the fabrication of OHPs across macro to micro scales, followed by rigorous performance testing under controlled thermal conditions.
Skilled in experimental instrumentation and data acquisition for thermal and fluid systems. Key capabilities include:
Proficient in using precision instruments and calibrated sensors (thermocouple, pressure sensor, flowmeter) for acquiring high-quality experimental data with minimal experimental uncertainity
Experienced with NI DAQ systems, PID controllers, solid state relay and compatible modules for real-time data collection
Developed a custom LabVIEW program to:
Continuously acquire data from pressure sensors (analog voltage output), flow meters (analog voltage output), and thermocouples at a very high frequency of 1612 data points each second
Display real-time plots and trends during experiments
Log data into TDMS files with accurate time stamps for post-processing and analysis
Achieved synchronized image capture from a high-speed camera and an IR camera along with thermocouple and pressure transmitter data, by triggering both cameras using an external TTL voltage signal
Proficient in Python, MATLAB, Origin, Mathematica, Mathcad for a broad range of scientific computing and data analysis tasks. Some of the work includes:
Data analysis and curve fitting for interpreting complex experimental datasets
Image analysis to identify vapor and liquid phases in multiphase flows using high-speed camera footage
Skilled in advanced techniques such as:
Fast Fourier Transform (FFT) for frequency-domain analysis
Numerical methods for solving partial differential equations (PDEs) especially for computational fluid dynamics (CFD) and heat transfer application
Machine learning model development, including linear regression and deep neural networks
Creating clear, insightful plots and visualizations to communicate data trends and experimental outcomes