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Saikiran Gopalakrishnan

Senior Digital Twin & Simulation Engineer specializing in AI-driven manufacturing automation

Chicago, ILSenior Technology Analyst – Product Design Automation Lab9 years experienceSeniorConsultingAerospace & DefenseAutomotive
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About

PhD-trained engineer with ~3.5 years of consulting experience building simulation/ML-driven manufacturing software. Deployed an ML surrogate model as a .NET C# DLL integrated with MES workflows, and resolved a critical pre-production latency issue by redesigning serialization/storage. Also built Python-based integrations across CAD/CAE tools and cloud material databases using an XML data model, with a strong interest in digital twins and real-to-sim/sim-to-real robotics workflows.

Experience

Senior Technology Analyst – Product Design Automation LabEngineering Group, Industries eXcellence Division (Eng IndX)
Graduate Research AssistantPurdue University

Education

Purdue Universitydoctorate, Aeronautics & Astronautics (Specialization: Digital Twin, Structures & Materials) (2022)
Purdue Universitymaster, Aeronautics & Astronautics (Concentration: Structures & Materials, Systems Engineering) (2018)
National Institute of Technology (Trichy, India)bachelor, Materials Engineering (2016)

Key Strengths

  • End-to-end deployment of ML surrogate model into production via .NET C# DLL for manufacturing users
  • Diagnosed and resolved production-blocking latency by changing serialization/storage approach (file-based to byte-based)
  • Performance validation via unit tests under varying loads and stress testing with customer team
  • Deep experience integrating CAD/CAE tools and cloud material databases via Python APIs and custom wrappers
  • Designed XML-based data model/schemas and built Python APIs for structured cross-tool data exchange
  • Strong customer-facing consulting approach: workshops, gap identification, scope discovery, and transparent communication
  • Experience collaborating with MES teams and aligning solutions to both technical stakeholders and end users

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Languages

English

Skills

Digital TwinSimulation Software DevelopmentSimulation Data AutomationMachine LearningTechnology ConsultingClient Requirements GatheringCAD-Based Simulation3D VisualizationLaser Ray TracingAutonomous Vehicle Sensor ValidationGeometric Feature DetectionGeometric Measurement ReportingDesign for Manufacturability (DFM) ChecksSurrogate ModelingSupervised Learning