Dr. Viraj V Patil
Islampur
Summary
Highly specialized Additive Manufacturing and Mechanical Engineer with a Ph.D. and strong industrial expertise in Laser Powder Bed Fusion (LPBF/SLM), alloy development, and powder engineering. Demonstrated success in process parameter optimization, defect mitigation, and advanced material characterization, with a deep understanding of microstructure–property relationships, delivering high-performance components across aerospace, biomedical, and industrial applications.
Overview
8
8
years of professional experience
Work History
Senior Application Engineer - Additive Manufacturing
Imaginarium India Pvt. Ltd.
Mumbai
09.2025 - Current
- Optimizing LPBF processes using GE Mlab systems for high-precision metallic components
- Developed novel alloy powders using ultrasonic atomization (AMAZEMET)
- Conducted PSD, XRD, and EDS for powder qualification and process reliability.
- Improved surface integrity, mechanical properties, and build repeatability
- Contributed to material database development and qualification frameworks.
- Collaborated with product development teams to integrate new features into existing applications.
Senior Application Engineer - Additive Manufacturing
Primaeam Solutions Pvt. Ltd.
Chennai
07.2024 - 08.2025
- Operated and optimized metal AM systems (SLM 280, GE M2), processing high-performance alloys (Ti-6Al-4V, IN718, SS17-4PH), improving build consistency and reducing print failures.
- Led design feasibility analysis and topology optimization, achieving material savings and weight reduction while maintaining performance.
- Implemented DFM/DFA strategies, reducing post-processing effort and improving manufacturability and production efficiency.
- Optimized material selection and process parameters, enhancing mechanical properties and reducing production cost.
- Conducted advanced metallurgical characterization (XRD, SEM, EDS, TEM), enabling defect identification and microstructure improvement.
- Performed high-precision dimensional inspection using GOM 3D scanning, ensuring tight tolerance compliance and minimizing deviations.
- Applied mathematical modeling & simulation for defect prediction and process optimization, reducing trial-and-error iterations.
- Contributed to R&D initiatives in alloy development and powder optimization, driving additive manufacturing innovation.
Ph. D. Scholar, Teaching cum Research Assistant
Vellore Institute of Technology
Vellore
03.2021 - 07.2024
- Research on SLM of 13Ni400 maraging steel
- Studied microstructure evolution, tribology, and corrosion behaviour
- Published multiple papers in high-impact journals
- Worked on heat treatment and surface modification techniques
- Utilized SEM, Optical Microscopy, Thermo gravimetric Analysis (TGA), Differential Scanning Calorimetry (DSC), FTIR, and other techniques.
- Mentored undergraduate students in material testing and additive manufacturing projects.
- Proficient in data analysis and technical writing (research articles, technical reports).
R&D Engineer - Mechanical Design
Challenger Sweepers Pvt. Ltd.
Pune
10.2019 - 01.2021
- Designed innovative mechanical systems (side brooms, linkages, brackets, frame structures) for industrial vehicles.
- Managed prototyping, mechanical testing, and product validation activities.
- Conducted feasibility studies, material selection, and cost-benefit analysis for design changes.
- Worked extensively with UGNX, CATIA, and SOLIDWORKS for product modeling and simulations.
Intern - Mechanical Design Engineering Department
ThreeM Software solutions
Pune
09.2018 - 09.2019
Education
Ph.D. - Metal Additive Manufacturing (3D Printing)
Vellore Institute of Technology
Vellore, Tamilnadu, India07.2024
Masters - Mechanical Production Engineering
Rajarambapu Institute of Technology
Islampur, India05.2018
Bachelors - Bachelors of Engineering (B.E.)
Annasaheab Dange College of Engineering and Technology
Ashta, India05.2016
Skills
- Metal Additive Manufacturing (SLM, LPBF, or EBM)
- Process Parameter Optimisation and Build Strategy Development
- Powder metallurgy and phase transformations
- Ultrasonic Atomisation & Powder Processing
- Microstructure–Property Correlation
- Heat Treatment and Surface Engineering
- Failure Analysis and Defect Characterisation
- Materials Characterisation (SEM, TEM, XRD, EDS, OM)
- Mechanical testing (tensile, hardness, wear)
- CAD/CAE (CATIA V5, Siemens NX, SOLIDWORKS, Fusion 360)
- Additive Manufacturing Software (Materialise Magics, Simufact Additive - Metal AM Process Simulation)
- 3D Scanning & Inspection (GOM)
- Statistical Optimization (Taguchi, RSM, DOE, Box-Behnken)
- AI/ML Techniques (ANN, PSO, Cuckoo Search)
- Data Analysis & Predictive Modeling (Minitab, Origin, Design Expert)
Custom Section
2021-12-01, 2022-05-31, Visiting Researcher, TAL TECH University, Tallinn, Estonia
Publications
- V. V. Patil, K. G. Prashanth, and C. P. Mohanty, Spark plasma sintering of 13Ni-400 maraging steel - Enhancement of mechanical properties through surface modification, J. Alloys Compd., 960, 170734, 2023
- V. V. Patil, C. P. Mohanty, and K. G. Prashanth, Selective laser melting of a novel 13Ni400 maraging steel: Material characterization and process optimization, J. Mater. Res. Technol., 27, November, 3979-3995, 2023
- V. V. Patil, C. P. Mohanty, and K. G. Prashanth, Parametric optimization of selective laser melted 13Ni400 maraging steel by taguchi method, J. Manuf. Mater. Process., 8, 52-65, 2024
- R. K. Shastri, V. V. Patil, C. P. Mohanty, and K. G. Prashanth, Optimizing the Electrical Discharge Machining Process Parameters of the Nimonic C263 Superalloy: A Sustainable Approach, J. Manuf. Mater. Process., 8, 3, 126-138, 2024
Awards
- Rank Holder, Rajarambapu Institute of Technology
- Completed an Orientation Course on Accelerators and LASER's, RRCAT
Languages
English
Proficient
C2
Marathi
Proficient
C2
Hindi
Proficient
C2
Projects
- Optimization of Maraging Steel and 17-4PH Steel Components using SLM, Improved mechanical properties through design and process innovations.
- Reduction of wastage of gas atomized powder in SLM process
- Design of New Side Broom Mechanism, Developed a new cleaning mechanism with optimized strength-to-weight ratio and manufacturability.
- Surface Treatment for Enhanced Wear Resistance, Designed experimental studies on coatings for improved tribological properties.
Hobbies and interests
- Singing
- Travelling
Disclaimer
I hereby declare that the above information is true to the best of my knowledge.
Timeline
Senior Application Engineer - Additive Manufacturing
Imaginarium India Pvt. Ltd.
09.2025 - Current
Senior Application Engineer - Additive Manufacturing
Primaeam Solutions Pvt. Ltd.
07.2024 - 08.2025
Ph. D. Scholar, Teaching cum Research Assistant
Vellore Institute of Technology
03.2021 - 07.2024
R&D Engineer - Mechanical Design
Challenger Sweepers Pvt. Ltd.
10.2019 - 01.2021
Intern - Mechanical Design Engineering Department
ThreeM Software solutions
09.2018 - 09.2019
Ph.D. - Metal Additive Manufacturing (3D Printing)
Vellore Institute of Technology
Masters - Mechanical Production Engineering
Rajarambapu Institute of Technology
Bachelors - Bachelors of Engineering (B.E.)
Annasaheab Dange College of Engineering and Technology