Aerospace Mechanical Engineer Thermal Systems Expert

SACHIN PINTO

Email: ******.*******@*****.***

Contact: +91-886*******

CAREER OBJECTIVE:

An aerospace professional with multidisciplinary experience in propulsion projects, aerospace oil cooler design, hand calculations, experimental performance and validation. Aero-structure composite design and manufacturing. Skilled in CAD/CAE tools, PLM systems and aerospace development workflows. Eager to apply my technical expertise in innovative projects while continuing to grow professionally.

EDUCATIONAL QUALIFICATION:

B.E. in Mechanical Engineering, Nitte Meenakshi Institute of Technology (Autonomous), 2009 – 2013, 7.09 CGPA.

TECHNICAL SKILLS:

•Modeling Software: Solid Works, Unigraphics Nx12

•Programming Language: LabView (Data Acquisition System)

•Product Life Management: TeamCentre 12.4

•Non Destructive Testing (NDT): Certified ASNT level II in PT, MT, RT with 6 months hands on experience.

•MS Package: Excel, Power Point, Word

ACHIEVEMENTS:

•2025: Participated in ASME International Mechanical Engineering Congress & Exposition 2024 (ASME, IMECE Hyderabad), journal selected on “Design and Development of Thermostatic Pressure Relief Bypass Valve (TBV)”, journal paper published on 3/12/2025.

•2024: Letter of appreciation from TVS Motors Pvt. Ltd., R&D Department, Hosur Tamil Nadu for successful completion of four heat exchanger executions of test rig setup, thermal performance and pressure drop evaluation, validated report with heat load deviation achieved less than 5%.

•2013: Certificate of Appreciation by The Honorable Minister For Higher Education and Tourism of Karnataka Shri. R. V. Deshpande, For Building The World’s Smallest Wheel Base Car On 27th May 2013.

PROFESSIONAL EXPERIENCE:

Council of Scientific and Industrial Research – National Aerospace Laboratories (CSIR–NAL)

Project Associate II – Propulsion & Heat Transfer Lab

Aug 2024 – Present Bengaluru, India

Designed and performed hand calculations for two-pass Air-Cooled Oil Cooler (ACOC) across multiple flight cases; selected appropriate materials and co-ordinate manufacturing processes.

Designed airflow ducts, conducted boundary layer verification using velocity probes and pitot tubes.

Successfully orchestrated test rig set up for experimental evaluation of aerospace oil cooler using pitot tubes (static and total) as per ISO 3966 standard, RTDs and Pressure Transducers and Mass Flow Meters placed at precise locations.

Analyzed and processed data acquired via LabVIEW Data Acquisition System (DAQ) to determine thermal performance and pressure drop using relevant formulas and plotting graphs using Microsoft Excel for performance evaluation and design optimization.

Collaborated with multidisciplinary team of researchers to deliver test results, design modifications and data interpretation.

Designed and developed connectors and fixtures using SolidWorks, supporting mechanical design efforts onto the structure as per aerospace standards.

Designed and developed Thermostatic Pressure Relief Bypass Valve (TBV); determined aerospace grade paraffin wax force generated and rate of expansion characteristics. Spring calculations to ensure proper thermal and pressure relief response incorporated together to perform within operational limits.

Designed and fabricated custom chamber for TBV at a specific controlled expansion gap and planned experimental test rig setup to determine thermal expansion and pressure relief response of TBV using Mass Flow Meters, RTDs and Pressure Transducers. Analyzed and concluded accurate results using Microsoft Excel.

Prepared certification documentation and report generation of Environmental and Acceptance Tests as per RTCA DO-160G and MIL-STD-810G.

Designed and developed complete layout and schematic for a new thermal test rig facility including civil planning and utility routing.

Performed detailed thermal and flow calculations for sizing of oil heaters, air heaters, Brazed Plate Heat Exchanger (BPHE), and chiller unit based on heat load requirements.

Selected instruments (temperature, pressure, flow sensors) and finalized optimal placement to ensure accurate measurement and system reliability.

Managed procurement of mechanical components and coordinated installation of air and oil piping lines from heat exchanger unit.

Ensured system performance validation, safety compliance, and thermal efficiency optimization during commissioning.

Hindustan Aeronautics Limited (HAL) (via Shripad Engineering Consultancy Pvt. Ltd.)

Design & Thermal Engineer – Rotor Wing R&D

May 2023 – Aug 2024 Bengaluru, India

Oil cooling system using Air-Oil Cooler and Fan arrangement.

Advanced Fuel Cooled Oil Cooler (FCOC) to improve fuel efficiency and work in confined space giving advantage in military application.

Main gearbox cooling system for emergency cooling device as back-up in an unfortunate scenario of primary system failure.

Actively involved in development of aero structure design of 3 and 5.5 ton class helicopter applying German Standards (LN, DIN & MBBN).

Drafting of structural machined and sheet metal components based on design compendium and having fair knowledge of GD&T. Selection of metallic and composite materials. Drafting of monolithic and metal sandwich composite well acquainted with layup scheme and curing cycle.

Product life cycle management, repair, rework and disposition of helicopter.

Well versed with primary and secondary structures, worked on bottom structure, frames, front fuselage, center fuselage, tail boom and empennage.

Preparation of integrated layouts, relevant to 2D drawings and related documents for assemblies, sub assemblies and main assemblies.

Interacted with international and end user on modification of design part.

PROPREITORSHIP

‘The Ceramic Studio’. Retail store of home décor products.

Jan 2019 – Jan 2023

Jamsons Air Conditioner Sales & Services

Executive Engineer

Nov 2014 – Aug 2018

Managed operations including technical service coordination, inventory management, and customer engagement.

Developed strong problem-solving and coordination skills in field service environments.

PROJECTS:

Setup of Thermal Test Rig Facility: Executed layout planning, schematic development, and instrumentation selection. Performed hand calculations for sizing oil & air heaters, BPHE, and chiller unit, and supervised installation of air and oil piping lines to ensure efficient system performance and successful commissioning.

Thermostatic Pressure Relief Bypass Valve (TBV): Designed a novel Thermostatic Pressure Relief Bypass Valve (TBV) integrating thermal expansion and pressure relief in a single unit for oil cooling systems. Led design, analysis, manufacturing, and real-world testing, achieving improved fuel efficiency and faster cold starts.

Air Cooled Oil Cooler (ACOC): Designed and tested an ACOC for a closed-loop oil cooling system, including hand calculations and experimental evaluation of an aerospace oil cooler using an ISO 3966–compliant test rig.

Fuel Flow Sensor: Engineered a lightweight helicopter fuel flow sensor with magnetic pickup, optimizing miniature turbine design, bearings, and materials for high-temperature engine environments while meeting aerospace standards.

Rotor Brake Hand Pump Assembly: Adhered to grievances of user and made necessary modifications and ensured the rotor blade stoppage within 40 seconds of brake application.

DECLARATION:

I hereby declare that the above mentioned information is correct up to my knowledge and I bear the responsibility for the correctness of the above mentioned particulars.

Place: Bengaluru (Sachin Pinto)

Contact this candidate