Santhosh Kumar Venkatachalapathy from India applies for Blue Card Germany

Mechanical engineers

Personal data:

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with the following Applicants-ID: 12455


Name of profession: Mechanical engineers Name of latest business sector: UTC Aerospace Systems Latest occupation/title: Senior Engineer Latest main activities: Design of metallic and composite aero structures, Both primary and secondary structures, Expert in using tools CatiaV5, Enovia, CPD & FiberSIM.


Completed education: bachelor Title or Qualification: Bachelor of Engineering Specialisation: Mechanical Engineering Additional trainings:

Preferred countries:

1. Preferred country | region / city: Germany | 2. Preferred country | region / city: United Kingdom | 3. Preferred country | region / city: France |

Language skills:

1. Language skills: english => excellent 2. Language skills: 3. Language skills: =>

Personal note /detailed application:

Respected Sir/Madam,
I am currently working with UTC Aerospace as Senior Engineer. I am actively looking for opportunity to work in Germany. I have gained my experience with product based companies like National Aerospace Laboratories (Indian R&D Lab), UTC Aerospace systems.
I come with nearly 7 years of experience in primary and secondary structure (composite and metallic) design.

Our Clients: - C-Series Bombardier, Mitsubishi Regional Jet, Airbus320neo.

Here is my detail work experience.


• Graduated in Bachelor of Engineering (2002-2006) – Mechanical.

Product Design Experience includes –

• Developing and validating design configurations and implementing the best design.
• Design Engineer with extensive experience of Aircraft Structures Design (Primary & Secondary) to work with a team to create and update detail and assembly drawings, incorporating engineering change notes, achieving delivery to time cost and quality.
• Creating a structural layout, ICD, ICY
• Ability to develop technical solutions, compliant with requirements within agreed programmes and timescales.
• Responsible for producing summary and detailed PDR / CDR presentation material when required.
• Optimization of implemented design for further weight savings and improving the performance of product.
• Manage and complete preliminary design schemes, trade studies and documenting the same for future reference.
• Creating the detail designs and assemblies for use in manufacturing the aircraft and its components.
• Frequent discussions with production experts and understand the requirements and also solve if any problems occurred in released drawings.
• Capturing lessons learnt, Creating SJI’s (Standard Job Instructions) for all the developed and developing programs.

Tool Skills –

Composite design in FiberSim 2009-2010 (Certified by Vistagy USA), CatiaV5 R19 (GSD, part design, assembly design, Composite part design module (CPE/CPD), FT&A, DMU basics), AutoCAD, Team centre, EnoviaV5 VPM.


• Received a spot award and Employee of the month from UTC Aerospace Systems (legacy Goodrich) for providing the valuable design suggestions, weight saving concepts and conducting the cross domain learning sessions within the team.


• Organization : - UTC Aerospace systems, Aero structures division, Bangalore-560048.
• Designation : - Senior Design Engineer.
• Period of service : - June 07-2010 to till date (Nearly 3 years).
• Company website : -
Legacy company -
Job Profile

Name: Blocker doors design and pressure shell for GTF (geared turbo fan) program
Client: (C-Series Bombardier, Mitsubishi Regional Jet, Airbus320neo)
Description: Blocker doors are the integral part of thrust reverser of a nacelle. Function of the blocker doors is to block the fan duct air during reverse thrust enabling the cascades to redirect the fan air in a forward direction and thus provide reverse thrust. Achieving the necessary acoustic area, manufacturability, fool proofing and weight are the few major considerations for the design. Pressure shell acts as a barrier in fan duct area to avoid leakage of air pressure which flows in bypass region.

Roles and responsibilities:
1. Worked on concept generation.
Generated design concepts as per the customers requirements. The concepts include selecting material, basic dimensions of product, trade studies of legacy programs, implementing common parts to reduce no. of assemblies, study of product manufacturing cost impact, study of hardware’s required, generating effective acoustic surfaces and more. I had captured lessons learnt and created several standard job instructions (SJI) for the ease of project and team members.

2. Trading of metallic and composite bond panels
We had metallic bond panels earlier, which were costing in weight. To maintain strict weight requirements I prepared trade study between metallic and composite bond panels. Finally, we implemented composite bond panels by showing the value addition parameters for the program.

3. Adopting Mistake proof design
This method was implemented to avoid wrong assemblies of doors. I came up with few concepts and same were implemented during the design phase.

4. Developing lay-up sequence for complete bond panel using composite design guidelines
Though I was aware of composite design guidelines, yet it is mandatory to go with Goodrich standards. Lay-up sequence, orientation are followed as per company’s design guidelines.

5. Finding out the possible acoustic area.
I have developed best effective acoustic surfaces. Client’s expectation was met in acoustics.

6. Ply stack-up and determining the sacrificial ply requirement
Determining the sacrificial plies needed for housing the fittings. Since our bond panels have curvature at the top and fittings are flat, we need to implement sacrificial plies for metallic fitting housings.

7. Optimizing the design to achieve least weight and better acoustics (major requirements)
Weight and acoustics are critical in our project. More acoustics and least weight are the requirements. I have met all the acoustic expectations and target weights as well.

8. Addressing the issues like corrosion, drainage requirement, avoiding knife edge of fasteners, Installation of wear pads (metal pieces bonded on to the composite bond panels).
Using composite and aluminium is become vast in aerospace. The assembly or interaction between composite and aluminium leads to corrosion. I have addressed these issues and solved by introducing isolation plies in between.

9. Relational design of complete assembly of blocker doors in CATIA. Creating composite ply definitions using CPD/CPE and FiberSim tools.
To avoid different approaches of different designers, we created a relational model layout which contains all important surfaces published, which are enough to build a models. I have taken the ownership of all these models and updated models when required.

10. Interacting with designers working on interfacing components and manufacturing support staff from shop floor.
Every day there is an interaction with staff working in Goodrich, CA, USA. We will receive the information’s required regarding project from them. We interact with manufacturing engineers to know if they have any issues and I solve them immediately ensuring no major concerns.

11. Designing composite bond panel using FiberSim, checking the produce-ability of the plies and addressing the concerns if any. Providing flat patterns and laser projection data to shop floor.
Goodrich uses FiberSim tool for detail designing the composite structures. I have been trained and successfully I have learnt in very short time and completed the detail design of blocker doors on time. I have captured lessons learnt and same was implemented on upcoming projects and also I am giving training for new employees as well.

12. Generating MBD of all the components per BOM using FT&A workbench in CATIA.
Generating detail design for manufacturing using FT&A tool in Catia. All metallic parts have to be detail designed for next phase. This is most important phase as we are releasing our designs for manufacturing. In order to avoid revisions, rework or errors, I have developed few checklists which ensure the drawings are delivered in right manner and with free of errors.

13. Tracking lessons learnt and implementing the same.
It may be technically or managerial, in every stage of project I capture the lessons learnt and update every week on project board. This makes every next project to go in easy way.


• Organization : - National Aerospace Laboratories, Advanced Composites Division,
Research and Development, Kodihalli, Bangalore-560017.
• Designation : - Worked as Structural Design Engineer under scientist.
• Period of service : - Aug 06 to June 02’2010. (4 years)
• Company website : -

Job Profile

Project Name: Composite wing design for SARAS-PT3 program
Client: IAF (Indian Air Force)
Description: SARAS, the country’s first civilian transport aircraft, has been designed by NAL. The wing for the production version has to meet the strict weight budget of the SARAS program. In order to realize the weight saving, it was felt that the wing should be the state-of the- art composite wing.
The only defence R&D organization in India to design and develop first ever composite wing.

1. Structural and Mechanical Testing, Design of Fixtures, test rigs and design of test setup.
I was Responsible for load setup scheme. Also worked as manufacturing supervisor for metallic fittings fabrication. Since this was my first job, I did lot of errors and I learnt through several trial and errors and implemented the best scheme after discussing with manager.

2. Design of primary composite structure-Spars and skins on both inboard and outboard.
Primary structures are very critical and needs extra attention while designing. I generated the 2D layouts of wing primary structures by collecting basic inputs from stress team. This was used by entire team to work on each individual part. I was also responsible for finding out the possible clashes during assembly design phase and coming up with the solution for the same.

3. Design of Wing/Fuselage Metallic Attachment Brackets and its assembly.
This is one of the most critical assemblies in aircraft. I worked out these models by ICY points. Ensuring the brackets is modelled at exact location. I have optimized around 12 grams of weight in these structures.

4. Design of Landing Gear Housing Metallic and composite Beams.
There are 2 beams in wing which holds the landing gear components. I have optimized around 8 grams in these structures.

5. Design of Fibre Metal Laminate (a new technology)-Nose Box Assembly. (For Bird Impact)
I was responsible for creating the basic layout for nose box of wing. By discussing with our senior scientists I collected the basic information to build a layout, which gives some basic idea to start with. After this, I started working on each part and assemblies. In nose box assembly I have reduced number of assemblies required.

Key Roles and responsibilities:

1. Worked on concept generation.
2. Developing lay-up detail for complete wing primary and other structures using composite design guidelines.
3. Finding out the possible solutions during assembly design phase.
4. Optimizing the design to achieve least weight and better results.
5. Addressing the issues like corrosion, avoiding knife edge of fasteners and also providing the valuable suggestions for the same.
6. Interacting with senior designers in team and also working on interfacing components and manufacturing support staff from shop floor.
7. Designing composite structures using AutoCAD, checking the layer shapes and no. of layers required for production.
8. Releasing the drawings for production and follow up the same. Solving any issues if concerns raised from manufacturing bay.
9. Generating detail drawings of all the wing components as per organization standards.
10. Design support for stress team activities.
11. Managing the work of Co-workers and making sure that their designs are passing in all aspects such as design standards, production standards and meeting other quality requirements.

Training Programs Attended:
FiberSim CEE and ACEE
CPD Training, Singapore.

Professional Achievements:
1. Presented a technical talk on “Composite wing design and development” at Knowledge sharing program conducted by Design department of Goodrich Aero structures, Bangalore, India.
2. Successfully trained a team of 8 members about basics of “Composites and metallic design, CatiaV5” at NAL, Bangalore, India.


B.E. (Mechanical Engineering)
First Class Grade


I strongly believe in the fact that there is no short cut to success and that there is no substitute for hard work and dedication. My willingness to learn and my adaptability to various situations have been my forte. I get along well with everybody and I am a team man to the core.


Nationality : Indian
Date of Birth : Jan 23, 1985
Sex : Male
Marital Status : Married
Languages Known : : English, Hindi, Kannada, Tamil and Telugu
Passport No. : H8029285


• Traveling, Presentations, Collecting information on air crash investigations, Organizing “Fun at work” events, Football, Cricket and Music.

I here by conclude that the information given above is absolutely trusty and true.



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