Sumeru

Sumeru Nayak Riverside, CA | Cell No:- | E mail-   Forward thinking structural engineer with a strong background in structural design and materials research (7+ years of combined industry and research experience) leading to novel polymeric systems for sensing applications in durable infrastructure, corrosionresistant coating systems and multiphysical (thermomechanical, electromechanical, fluid-structure) computational models for virtual testing of fiber composites, concrete, porous media and thin films Excellent team player with strong leadership skills thus driving successful collaborations towards basic research while fulfilling industry driven applied research leading to 12+ journal publications and 3+ IPs Creative and self-motivated individual with strong interpersonal skills established in North America/Asia thus facilitating easy integration in multicultural environments; proven ability of bringing in novelty with attention to unique details while meeting deadlines in a fast-paced work environment Professional Experience Advanced Research Engineer, James Hardie Building Products R&D, Fontana, CA o o o o o o o o o o 01/2022-present Delivered computational modeling framework with 85%+ accuracy prediction of surface pattern defects under stacked loads with complex texture Delivered custom coded patterned random particle generation algorithm for masking surface defects resulting in cost savings of $40M+ and US patent filing Delivered COMSOL co-simulation models for cross-directional indents on manufactured boards resulting in new product development with $10M + market potential Delivered OSS geometry rendering environment for computational analysis of complex geometrical texture from Blender to COMSOL using custom codes developed in Python & Java Implementation of non-linear material models for improved prediction accuracy in deformation characteristics & rheological behavior Rapid prototyping & Development of coding environment to parse G-code used for CNC/3D printing for export to surface geometries to increase efficiency of existing manufacturing trial techniques Experimental determination of surface characteristics & data analysis for defect analysis/identification/model validation Design of Experiment (DoE) for new products development (NPD) Geometric analysis and quality assurance of new concepts/products Optimize, modify the operational paths for existing equipment for compatibility with new product designs Additional Role: Data Science Lead North American Team o o o Developed computer vision based density clustering for determining texture characteristics of digital designs Metrology for surface quality determination with synergistic application of lasers, photometric stereo 3D scanner and linear scanner with transformative rasters, point clouds, stereolithographic and digital elevation models Implement quality measurement sensors & programming interface on assembly line; Variable aperture for slicing digital design files for analytical computation of surface features Technical Lead, Panda Industries Inc., Narragansett, RI o o o o o o Associate Design Engineer, Fluor Corp., India o o o o 09/2020-12/2021 Team Lead of engineers for development of 3D printable sustainable technologies for construction with reinforced concrete (US Patent in preparation), awarded $0.25M by National Science Foundation; Maintaining project schedule, budget and quality control Process Design: Delivered 53% cost savings with no requirement for concrete formworks and 25% time savings with high throughput 3D printable filament, as compared to conventional concreting Design for Assembly of prototype 3D printer with flexible assemblies leading to cost savings of >40% by eliminating the need for auxiliary structures during large-scale 3D printing of residential and commercial buildings, as compared to 3D printing construction competitors New Process Development: Achieved 5% reduction in CO2 emissions by developing sustainable bamboo-based fillers for enhanced fiber-reinforced composite systems employed in 3D printing New Product Development: Achieved 30% cost savings for wheat-based green adhesives for lumber strand boards and eliminated VOC emissions by replacing formaldehyde Design for Manufacturability: Delivered 15% energy savings for hot press technology during large-scale manufacturing of soy-based lumber strand boards by optimizing fiber layup process leading to direct cost savings of 5% and strength enhancement of 20% 06/2014-07/2015 Drafting and designing structural components for modular construction of Oil & Gas Pipe Racks, Pressure Vessel foundations and piping loads manufactured at Hyundai SK and installed in Suncor Fort Hills, CN Undertook design of steel pipe rack for lifting/transportation/modularization with RISA-3D and anchor bolt, base plate design with RISA-Base following codes CSA-S16, ACI 318 and ASCE 07 Teamwork with piping, electrical and HVAC for miscellaneous discipline support (MDS) Delivered request for evidence (RFE) with substitute beams and Finite Element Analysis for on-site technical support Page 1 Education Ph.D. in Civil Engineering- Materials and Structures University of Rhode Island, Kingston, RI, USA Aug 2017 – Aug 2020 Thesis: Multiscale & Multiphysics Modeling of Durable Infrastructure Materials M.S. in Materials Sciences- Corrosion Science Indian Institute of Technology (IIT), Bombay, INDIA Jul 2015 – Jul 2017 Thesis: Corrosion Studies of Coated & Uncoated Reinforcement Bars in Concrete Seminar: Application of graphene & composites in aerospace structures B.S (Hons) in Civil Engineering Jadavpur University, Kolkata, INDIA Jun 2010 – Jun 2014 Seminar I (UC Berkeley, CA): Electrochemical arsenic reduction (EAR) in ground water Seminar II: Application of bamboo in green buildings; Electronic Waste Management Areas of Expertise     Data driven (Inverse problems, Machine Learning, Least squares, Multivariate, Interpolation, SVD, PCA) Finite Element Analysis w/ Python, C/C++, FORTRAN scripting, ABAQUS, LS-DYNA, COMSOL Surface Metrology, Laser Systems, Quality Monitoring Fiber-reinforced Polymers Composites, Sensing Films       Alternate binders Spatial damage sensing Electrical impedance tomography (HFA,EIS) Fracture simulations Dynamic material performance (SHPB) Microstructure guided designs (SEM)       Multiscale Simulations Rheology and 3D printing Peridynamics Corrosion monitoring Building Codes Cementitious systems       Pipe rack, foundation design Multiphysics (electro/thermomechanical) Marine structures Fluid-structure interactions Phase change materials (PCM) Piezoresistive; Self-sensing Projects/Leadership Computational Modeling of Manufacturing Defects in Surface Textures of Fiber Cement Boards (2022-present): o o o o o North America Team Lead: Design of Geometric Pattern for computational analyses; Multiphysical simulations of Manufacturing Processes; Prediction and Insights into panel defects Analyzing complex material characteristics; Computational Modeling for defects in fiber cement sheet products; Rendering of complex geometrical features using OSS: Python, Java, C Implementation of non-linear material models for improved prediction accuracy in deformation characteristics using Data driven (Inverse problems, ML, Least squares, Multivariate, Interpolation, SVD, PCA) Experimental determination of surface characteristics & data analysis for defect analysis/identification; Quality monitoring with Laser Surface Data using custom-built Python, HDF codes Establishing manufacturing techniques for scalability across global research teams; Development of coding environment to parse G-code used for CNC/3D printing for export to surface geometries Development of self-sensing materials and structures -): o o o o o o Analysis and Development of Sustainable and Alternative Infrastructure Materials -): o o 3D Printing & Processes for Large-Scale Construction -): o o NSF-SBIR $0.25M Project Lead: Delivered 53% cost savings with no requirement for concrete formworks and 25% time savings with high throughput 3D printable filament, as compared to conventional concreting; Design for Assembly of prototype 3D printer with flexible assemblies leading to cost savings of >40% by eliminating the need for auxiliary structures during large-scale 3D printing of residential and commercial buildings, as compared to 3D printing construction competitors Technical Support for bamboo strand board development at Panda Processing Inc, with material procurement, sustainable development and alternative materials, material testing, performance evaluation delivering cost cutting of 20% with optimized material design and manufacturing o o o Delivered efficient designs for 10,000 m rated composite cylinders manufactured at Goetz Composites, RI for Office of Naval Research Challenge Data-analytics computation of shock resistant coated composite cylinders under high strain dynamic loads: Multiscale simulations, FSI and experimental validation using ABAQUS, Python, sci-kit learn, LS-Dyna, Digimat, TexGen, Developed novel agro-sourced polymeric compositions with waste particulates ionomers for coatings/matrices Computational analysis of multiphysical correlations for hygro-thermomechanical, electro-mechanical, fracture response of multi-scale heterogenous systems using COMSOL C++ External Material, ABAQUS UMAT, XFEM, Peridynamics Peridgm, Delivered designs for construction and maintenance of composite materials for bridges in Rhode Island collaborating with Rhode Island Department of Transportation (RIDOT), RIMTA with 30% life-cycle cost savings Corrosion Protection Systems for Galvanized and Galfan-coated Metallic Reinforcement in Concrete during early stages of cement hydration -): o Hot-dip galvanization process for rebar coating at Tata Steel Company, India Experimental investigation of corrosion potential, Electrochemical Impedance Studies for correlating pH of hydration stages of concrete with design life of coating o List of Publications o Design & Analysis of Underwater Composite Structures -) Computational Analysis of nano-composite self-sensing composites with 90% + reversibility Demonstrated spatial damage-sensing with 85%+ efficiency in 20% metallic particulate incorporated binder with EIT; Dynamic Testing (SHPB, UTM, DIC), Micro & nano indentation Electrical characterization (HFA, EIS, Polarization) Microscopy (SEM, TEM); Chemical characterization (XRD) Developed and analyzed sensing woven fiber composites: Embedded nitinol sensors for 95%+ efficiency designed and fabricated with Nautilus Defense, RI using ABAQUS UEL, Python for ODB parsing, Digimat Awards/Honors  Professional Certification for Applied Data Science, Massachusetts Institute of Technology, USA (May 2022)   OSHA Certified by James Hardie R&D Toray Plastics America Fellow;  Committee Member Innovation Forum Council, JH R&D; American Society of Civil Engineers (ASCE) Page 2   Guest Editor; Reviewer at ACS, Elsevier; Featured Speaker at ACI Convention Frank Gabron & Kenneth Hylander Fellow