Vipul Sonkar

• Lead end-to-end operations of six industrial EOS metal additive manufacturing systems, including EOS M280, M290, and M400-4 platforms.

• Manage production planning, machine scheduling, powder inventory, process development, and technical execution to ensure maximum equipment utilization and on-time project delivery.

• Conduct feasibility assessments and DfAM reviews for aerospace, defense, automotive, and industrial components.

• Facilitated the manufacturing of over 500 complex metal additive manufacturing projects, maintaining quality and adherence to specifications.

• Develop optimized build strategies through orientation selection, support generation, nesting optimization, and production planning.

• Qualified process parameters for aerospace-grade materials including Ti6Al4V, Inconel 718, AlSi10Mg, SS316L, CoCr, and CuCrZr.

• Reduced manufacturing rejection rates by approximately 20% through process monitoring, troubleshooting, and continuous improvement initiatives.

• Coordinate annual maintenance programs, preventive maintenance schedules, and machine recovery activities with internal maintenance teams and OEM support.

• Lead post-processing activities including stress relief, heat treatment, support removal, machining coordination, and final inspection.

• Developed operational SOPs and process controls, achieving a 30% reduction in unplanned downtime and enhancing overall production reliability.

• Executed topology optimization initiatives, achieving weight reductions of up to 18% while preserving structural integrity of components.

• Optimized production-ready build files using Materialise Magics for aerospace, defense, automotive, and industrial applications, enhancing overall build quality.

• Performed model repair, orientation studies, support design, nesting optimization, and build preparation activities.

• Developed support strategies that reduced post-processing effort while improving build stability and dimensional accuracy.

• Executed additive manufacturing simulations with Simufact Additive to predict distortion, residual stresses, and build deformation, enabling proactive adjustments.

• Optimized build layouts for EOS production systems to improve machine utilization and manufacturing efficiency.

• Maintained full production traceability and documentation in compliance with AS9100 quality standards.

• Collaborated with design, manufacturing, and quality teams to refine process parameters and scan strategies, improving integration and output consistency.

Evaluated customer components for additive manufacturing feasibility and commercial viability.

• Supported DfAM implementation, enhancing manufacturability and decreasing production costs.

• Generated build files and support structures using Materialise Magics, ensuring project alignment with design specifications.

• Prepared manufacturing estimates, quotations, and technical proposals to facilitate informed decision-making.

• Coordinated between engineering, production, and commercial teams to ensure successful project execution.

• Conducted software testing and troubleshooting to ensure optimal performance.
• Collaborated with cross-functional teams to enhance product functionality.

• Assessed customer components for additive manufacturing feasibility and commercial viability.

• Supported DfAM implementation, enhancing manufacturability and decreasing production costs.

• Generated build files and support structures using Materialise Magics, ensuring project alignment with design specifications.

• Prepared manufacturing estimates, quotations, and technical proposals to facilitate informed decision-making.

• Coordinated between engineering, production, and commercial teams to ensure successful project execution.