Shailesh G.

I have 25 years of experience in applying physics-based methods (such as CFD, FEA, heat transfer, turbulence, mass transfer, bio-reactions, and chemistry), hand calculations, testing techniques, and statistical analysis across diverse industries, including aerospace, medical, semiconductor, apparel, footwear, gloves, automotive, and chemical processing. My expertise spans from concept development to prototype creation and commercial launch, with a focus on scaling processes and equipment from prototype to commercial scale. Many of these product developments are supported and validated by tests conducted in a cost-effective, technically balanced manner. I address significant uncertainties by making well-considered assumptions and approximations, often solving simplified 0D, 1D, 2D, or simplified 3D models with enough physics to guide product development, rather than solving the most complex real 3D geometries. I have worked with tools such as ANSYS Fluent, CFX, STAR-CCM+, CFD-ACE+, TAITherm, OpenFOAM, and ANSYS Mechanical for various applications. Key Contributions: • Collaborated with test and design engineers in developing next-generation engines for launch vehicles and spacecraft, including systems such as thrust chamber cooling, fuel/oxidizer pressurization, fuel tank filling and emptying, manifolds, injectors, diffusers, flow straighteners, and cavity purge analysis, using STAR-CCM+ and ANSYS Fluent. • Supported test campaigns, integrating CFD analysis with hotfire test data and ensuring the digital twin remained up to date. • Led component, subsystem, and product-level simulations to support design, development, verification, and validation efforts, ensuring performance in intended environments and conditions. • Developed thermal analysis models using ANSYS, STAR-CCM+, ACE+, and MSC Patran at various levels, including components, multichip modules, circuit card assemblies, subsystems, and systems, resulting in low thermal-risk hardware. • Created test plans and procedures that led to successful execution and results. • Identified and tested advanced thermal interface materials (TIMs). • Performed thermal analysis model correlations to refine predictions based on test data, enhancing understanding and accuracy. • Worked closely with customers and engineering teams to define the necessary testing to validate thermal analyses and ensure compliance with requirements. • Applied hand calculations and ANSYS Fluent thermal analysis to guide the design of evaporators and cooling plates. • Optimized advanced IC designs to ensure optimal thermal performance. • Utilized aerogel-based insulation composites to mitigate hotspots and meet touch safety requirements. • Conducted thermal analysis for fire testing of building construction and materials.