Balasundar Kuppusamy
Bangalore
Summary
Highly accomplished and results-driven Principal Engineer with over 19 years of experience in engineering simulations, analysis, and project leadership. Proven expertise in Finite Element Analysis (FEA) for structural, dynamic, and thermal systems, coupled with a strong background in team mentorship and project execution. Skilled in the application of AI/ML for manufacturing and testing, and a recognized patent holder in engineering design. Adept at managing projects from conceptual design through to qualification, consistently delivering accurate and timely results.
Overview
20
20
years of professional experience
Work History
Principal Engineer
Collins Aerospace
Bangalore
11.2013 - Current
- Spearheaded the project management and technical execution of multiple aerospace component qualification programs for clients like Boeing, Airbus, Rolls Royce and Embraer.
- Mentored and led a team of engineers, including managing a direct report for a one-year period, enhancing their technical proficiency and tool expertise, and fostering a collaborative, high-performance environment.
- Successfully executed the M2 Connector qualification project for an avionics electronics box, executed random and harmonic analysis as part of requirement analysis and an iterative design process that identified the final design meeting all regulatory and performance criteria before physical testing.
- Managed the development and analysis of the 0132AHJ3 TSAS sensor, leading the team in performing harmonic analysis on multiple conceptual designs to select the optimal one based on frequency response, resulting in a successful proof of concept and sine sweep testing.
- Directed the structural and dynamic analysis for the ED4 Angle of Attack sensor, ensuring compliance with vibrational loads and hail impact criteria, and successfully qualifying the probe for use.
- Oversaw the harmonic vibration analysis for three Rolls Royce TRENT7000 fire detectors, leading to well-received recommendations on material and assembly changes that were adopted by the Strategic Business Unit (SBU).
Lead Engineer
GE ITC PVT LTD
Bangalore
10.2006 - 11.2013
- Led the 7FA.04 Fast Ramp task based project from concept to completion, overseeing transient thermo-mechanical analysis and developing correlations to calculate LCF and fracture life for critical rotor zones.
- Directed the Root Cause Analysis (RCA) for cracks in the Frame 5 combustor, managing the iterative process of thermal data matching and thermo-mechanical analysis to accurately estimate LCF life and identify the cause of failure.
- Initiated and managed the MS5002D Transition piece Extendor kit3 project, leading a team to evaluate and propose design modifications based on durability and sensitivity assessments, ultimately extending the life of the transition piece.
Engineer
VIRTUAL ENGINEERING CENTER, INFOSYS
Bangalore
08.2005 - 09.2006
- Executed an iterative weight reduction program for the Boeing 787 dream liner's Nose Wheel Well Door, successfully identifying a lighter geometry with equivalent strength through a series of FEA simulations and design adjustments.
- Performed size optimization for the Nose Wheel Well Beams of the Boeing 787, applying size variables and constraints (buckling, static stress) to achieve weight reduction goals.
Education
Programme on Data Science & AI -
Indian Institute of Management (IIM-B)
Bangalore08.2025
M.E - Engineering Design
Anna University - CEG
Guindy05.2005
B.E - Mechanical Engineering
University of Madras
04.2002
Skills
- Technical: Structural, dynamic, and thermal FEA; AI/ML; root cause analysis (RCA); design optimization; Additive manufacturing
- Tools: ANSYS, ALTAIR HYPERMESH, MSCNASTRAN, MSCPATRAN, UG NX
- Management: Project execution, team leadership and mentorship, stakeholder management, requirements analysis, quality assurance
Accomplishments
- University Gold Medallist in M.E. Engineering Design.
- Scored 97.55 percentile on the G.A.T.E. 2003 examination.
Patents
1.Rail-mounted fire detection system
Patent number: 10760975
2. Liner aft end support mechanisms and spring-loaded liner stop mechanisms
Patent number: 8713945
3. ADDITIVE MANUFACTURED BOTTLE MOUNTINGS
Publication number: 20210245300
4. CLAMP FOR FIRE AND OVERHEAT DETECTION SYSTEM
Publication number: 20210128957
Timeline
Principal Engineer
Collins Aerospace
11.2013 - Current
Lead Engineer
GE ITC PVT LTD
10.2006 - 11.2013
Engineer
VIRTUAL ENGINEERING CENTER, INFOSYS
08.2005 - 09.2006
Programme on Data Science & AI -
Indian Institute of Management (IIM-B)
M.E - Engineering Design
Anna University - CEG
B.E - Mechanical Engineering
University of Madras
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