Materials & Process Engineer

Jayaraghul
Thangaraj Kannan

Turning materials science into engineering outcomes — from first principles to field‑ready solutions.

Monash University Graduate Vestas Award — Best Technical Solution Peer-Reviewed Publication FIFO-Ready · Full AU Work Rights
Jayaraghul Thangaraj Kannan — Materials and Process Engineer
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About

I am a Materials Engineering graduate from Monash University with a foundation in Mechanical and Advanced Manufacturing Engineering from SASTRA University. My core focus is failure analysis, root cause investigation, and closing the gap between material behaviour and process performance — in environments where getting it wrong has real consequences.

At SisterWorks Inc., I conducted structured RCA on safety-critical tram fleet components, isolated failure modes under mechanical load and fatigue, and translated findings directly into corrective action — through supplier liaison, compliance-mapped material selection (EN 45545-2, AS 1530), and production-ready documentation. At Falcon 3D, I commissioned a high-temperature FDM system from first principles, developed PEEK process parameters through structured DOE, and extended the asset's reliable operating envelope from 340°C to 450°C — delivering validated production capability at 81% below commercial cost.

I understand the language heavy industry speaks: equipment commissioning, process parameter optimisation, asset life extension, and structured documentation from observation through to corrective action. I work well in demanding, shift-based environments and take ownership of problems end-to-end.

Currently seeking graduate or entry-level roles in process and materials engineering across resources, heavy manufacturing, and infrastructure. Open to relocation and FIFO arrangements.

Experience

Engineering Experience

Engineering Intern

SisterWorks Inc.

Springvale VIC 3073, Australia

Jul – Dec 2025
  • Identified 5 failure modes (delamination, fatigue debonding, foam creep) across active tram fleet seat components via structured RCA — mapped each to a root mechanism and targeted corrective action.
  • Resolved material selection from a 3-candidate shortlist to a single compliant recommendation using a weighted scoring matrix across 8 criteria, including EN 45545-2 HL3 and AS 1530 — eliminating procurement ambiguity.
  • Compressed supplier evaluation cycles by converting findings into technical briefs that enabled direct feasibility and cost discussions with vendors without further engineering interpretation.
  • Produced end-to-end documentation — SolidWorks CAD, production drawings, and a structured technical report authored to SOP, Work Instruction, and OPL standards.

Additive Manufacturing Engineer

Falcon 3D – 3D Printing

Royapettah, Chennai, Tamil Nadu, India

2020 – 2021
  • Delivered PEEK printing at 81% below commercial cost (Rs. 93,125 vs Rs. 5,00,000) by designing, building, and commissioning a custom FDM system from first principles — full equipment verification, tooling integration, and process validation.
  • Achieved stable PEEK extrusion above 340°C through systematic parameter development — nozzle geometry, thermal profiles, feed rates, and cooling — across iterative process trials.
  • Reduced failures, waste, and defect rates through structured DOE — mapped process variable interactions to optimal operating windows, improving equipment availability and output consistency.
  • Extended operating range to 450°C via hot-end upgrade (nickel-plated copper block, bimetallic heat break, vanadium nozzle) and Marlin firmware v2.32x configuration — window informed by COMSOL thermal modelling.

Other Experience

Express Agent & Duty Manager Trainee

Hotel Holiday Inn Express

589/599 Little Collins St, Melbourne VIC 3000

2024 – Present
  • Managed end-of-shift operational handovers in a 24/7 high-volume hotel environment — documenting outstanding tasks, safety incidents, and unresolved guest issues to ensure incoming staff had full situational awareness and no operational gaps, mirroring shift handover discipline required in industrial and FIFO settings.
  • Progressed to Night Duty Manager training by demonstrating consistent judgment under pressure, rapid fault identification, and adherence to emergency response and OHS protocols — including fire evacuation procedures and lone-worker safety requirements across overnight shifts.

Education & Awards

Master of Professional Engineering

Materials Engineering

Monash University, Clayton VIC, Australia

Polymers · Functional Materials · Ceramics · Corrosion · 3D Printing of Polymers · Nanomaterials · Advanced Photovoltaics · Hydrogen Generation · Biomaterials · Biomechanics

2023 – 2025  |  GPA: 3.1

MTech (Integrated) in Advanced Manufacturing

with BTech in Mechanical Engineering

SASTRA Deemed University, Tamil Nadu, India

Lean Manufacturing · Plant Layout · Additive Manufacturing · Welding Technology · DFMA · TQM · Hydraulics & Pneumatics · Reliability & Maintenance Engineering

2016 – 2021  |  CGPA: 7.02

Award

Vestas Award — Best Technical Solution

Hydrogen Horizons Ideathon 2025 · Monash Energy Club & Latrobe City Council

Designed LATP AirLift — a three-phase liquid hydrogen supply chain for Latrobe Regional Airport, scaling from 2 to 8 hydrogen aircraft. Modelled AUD $16.99M CAPEX with a surplus H₂ and O₂ revenue stream reaching ~AUD $9.7M by Year 3. Judged best among all competing teams on simultaneous technical rigour and commercial viability.

Publication

Nozzle Flow Characteristics of PEEK Material in 3D Printing

Material TECH 2021 — Peer-Reviewed Journal

Two-phase final year project at SASTRA University, conducted alongside industrial work at Falcon 3D. Phase I used COMSOL Multiphysics to determine the 133–137 minute safe operating window before thermal degradation. Phase II applied those findings to physically fabricate a PEEK-capable FDM printer at Rs. 93,125 — 81% below the Rs. 5,00,000 commercial benchmark.

DOI: 10.1016/j.matpr.2021.02.004 ↗

Projects

Click any project card to explore the full details, process, and outcomes.

Completed budget PEEK FDM 3D printer fully enclosed in aluminium foil — built for Falcon 3D at Rs. 93,125
Published · Additive Manufacturing · Falcon 3D · COMSOL

Budget PEEK 3D Printer — Fabrication & Thermal Analysis

Built a PEEK-capable FDM printer for Falcon 3D at Rs. 93,125 — 81% below the Rs. 5,00,000 commercial benchmark. Phase I used COMSOL to model nozzle thermal degradation; Phase II applied those findings to fabricate and deploy the printer. Peer-reviewed publication.

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Decommissioned Yarra Trams seat showing surface wear and foam delamination
Failure Analysis · Materials Compliance · WIL Placement

Yarra Trams Seat Redesign

Sole engineer on a live industry project — failure analysis, standards compliance (EN 45545-2, AS/NZS 2269), material selection, CAD modelling, and supplier engagement for Yarra Trams' active fleet.

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P&ID diagram for tertiary wastewater treatment plant — equalization tank, MBBR reactor, microfiltration membrane system with full instrumentation
Process Engineering · Membrane Technology · LCA

Tertiary Wastewater Treatment Plant — Ballarat

Full detail design of a 6,000 m³/day Class A recycled water facility for the City of Ballarat. Led an interdisciplinary team of 5 across membrane selection, Aspen Plus modelling, P&ID, HAZOP, and financial feasibility. ~AUD $9M CAPEX, 6–7 year payback.

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Toyota 2.5-ton hydrogen fuel cell forklift — blue industrial forklift with FUEL CELL branding
Feasibility Study · Green Hydrogen · TCO Analysis

Hydrogen Fuel Cell Forklift — Feasibility

10-year TCO model and green hydrogen production strategy for a fleet of 10 Toyota fuel cell forklifts. Sized on-site PEM electrolyzer + 640 kW solar PV + 2 MWh BESS at AUD $2.66M CAPEX.

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Team LATP AirLift holding Vestas Award certificates at Ideathon 2025
Vestas Award · Hydrogen · Ideathon 2025

LATP AirLift — LH₂ Supply Chain for Regional Aviation

Three-phase liquid hydrogen supply chain for Latrobe Regional Airport scaling from 2 to 8 aircraft. AUD $16.99M CAPEX model with surplus H₂ revenue from Year 2. Won Vestas Award for Best Technical Solution.

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LPBF printed SS316 redesigned bracket — triangular A-frame geometry, physically manufactured at Monash University
Additive Manufacturing · DfAM · FEA · LPBF

Lightweight Redesign via LPBF

Redesigned a structural SS316 bracket using Design for Additive Manufacturing principles, achieving a 70.3% weight reduction (510 g to 151.45 g). Validated by FEA and physically printed via Laser Powder Bed Fusion.

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Finished 3D printed VarioShore TPU shoe insole with foot placed on top, showing the completed prototype from the Monash final year project
Biomedical · FDM · Materials Characterisation

3D Printed Customised Shoe Insoles

Final year project designing, fabricating, and mechanically testing FDM-printed insoles using VarioShore TPU with graded lattice structures. From SolidWorks FEA and material calibration through to physical prototypes tested on a ZwickRoell machine.

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Assembled FDM-printed PLA solar cell bracket mounted on test rod — full assembly of panel frame, ball-joint, and base
FDM · DfAM · Material Selection · Sustainability

FDM-Printed Solar Cell Brackets

Scaled-down prototype brackets designed to demonstrate how FDM can enable communities without grid access to manufacture solar mounting hardware locally. SolidWorks CAD, PLA fabrication on FlashForge Creator Pro, and full UN SDG 7 framing.

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Monthly energy distribution chart showing baseline and seasonal heating/cooling consumption from May 2024 to May 2025
Energy Audit · NPI Analysis · Heat Transfer · NPV

Residential Energy Audit — Richmond

Full energy audit of a Melbourne apartment: NPI benchmarked at 70.88 kWh/m²/yr, 717 kWh/yr HVAC load isolated via HDD/CDD, envelope heat loss quantified, and a costed improvement strategy delivered within AUD $30,000.

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Community & Engagement

Precious Plastics Monash (PPM)

Team TREnD Member · 2024 – 2025

  • Maintained and operated plastic recycling machinery including the extruder, shredder, and injection moulding unit.
  • Led Ender 3 printer enhancements for multi-material printing using prior FDM experience.
  • Completed inductions in light fabrication, welding, and maker space tools.
  • Contributed to first-year student outreach, demonstrating plastic recycling and introducing materials engineering concepts.

Monash Student Communities (MSC)

College Advisor · 2024 – 2025

  • Managed a team of 40 members as their advisor within a community of 800 students.
  • Organised events and team-building activities to enhance teamwork and camaraderie.
  • Guided students by directing them to necessary resources and support when needed.
  • Obtained a Working with Children Check as part of the formal advisor training.

Skills

Materials & Process Engineering

Failure Analysis & RCA Materials Selection & Compliance Process Parameter Development Equipment Commissioning & Validation Fire Performance Assessment (EN 45545-2 · AS 1530) Polymer & Composite Processing High-Temperature Extrusion (PEEK >340°C) CAPEX / OPEX Modelling Corrosion Engineering Design of Experiments (DOE) Asset Life Extension Scrap Reduction & Process Optimisation

Additive Manufacturing

FDM Process Engineering Metal AM — LPBF (SS316L) Design for Additive Manufacturing (DfAM) Build Orientation Optimisation Open-Source Hardware Development Marlin Firmware Configuration Multi-Material Printing

Simulation & Design Tools

COMSOL Multiphysics SolidWorks CAD & Production Drawings Finite Element Analysis (FEA) Thermal-Fluid Modelling Python Technical Sketching & GD&T

Professional & Communication

Root Cause & Corrective Action Reporting Supplier Liaison & Feasibility Assessment Technical Pitching & Presentation SOP / Work Instruction / OPL Authoring Stakeholder & Cross-functional Communication Project Management

There's more to me than process specs.

3D printing at home, building things, travel, and everything in between. Take a look at what I get up to outside of work.

Explore My Hobbies →

Let's Connect

Open to graduate and entry-level process & materials engineering roles across Australia. FIFO-ready. Full Australian work rights.