Electric Propulsion Systems for Aircrafts are all set to revolutionize the aviation sector in pivotal ways, not merely by reducing carbon footprint but also by enhancing affordability and reducing noise pollution associated with air travel.
Thurabudeen Sahul, our next pathbreaker, works as Power Electronics Mechanical Engineer at magniX (Seattle), a pioneering firm dedicated to advancing electric propulsion systems for aircraft applications.
Thurabudeen talks to Shyam Krishnamurthy from The Interview Portal about his most memorable moment witnessing the takeoffs of the 1st flights of new aircraft models retrofitted with the electric propulsion system that the team worked on !
For students, while creating cutting-edge solutions is commendable, real impact is made when your innovations are affordable to the masses. The broader the reach of your solution, the more profound its impact on society.
Thurabudeen, tell us about your background?
I was born and raised in Chennai, India where I grew up in a close-knit family consisting of my parents and a sister. While my mother dedicated her days to managing our household, my father worked as a cashier at a Co-Op store. My sister pursued her passion for numbers and earned a degree in mathematics.
From a young age, I was always a curious kid. Instead of just playing with toys, I found a greater thrill in dismantling them to understand how they worked. As I navigated through my teenage years, my interest shifted towards the working of motorcycles, a fascination fueled by a small motorcycle repair shop that was near my house. I would spend countless hours assisting the mechanics with various tasks. It didn’t matter if it was locating tools or participating in oil changes, as long as I was getting my hands dirty in the heart of mechanical tasks. My love for motorcycles and the intricate systems that propelled them only grew with time. This hands-on experience, coupled with the journey, led me to go on and shape my aspirations, eventually becoming the first-generation graduate in my family.
Throughout my school years and during my bachelor’s degree, I was more of a backbencher with a wide circle of friends. I was never near the top of the class, but I have a special fondness for math, scoring nearly perfect in board exams. I enjoyed my time during my bachelor’s degree. It was during my master’s when I became more focused, and started performing well academically.
What did you do for graduation/post graduation?
I did my bachelor’s degree in aeronautical engineering from Rajalakshmi Engineering College and master’s degree in mechanical engineering from California State University, Fresno.
Can you talk about some of the influences that led you to such an offbeat, unconventional, and cool career?
As mentioned earlier, my curious nature found a playground in the local motorcycle mechanic shop where I witnessed engine rebuilds, fixed leaky suspensions, and observed how air filters affected exhaust sound. This early exposure enriched my understanding and further stoked my curiosity, providing a perfect backdrop to the theoretical knowledge I would acquire later.
My fascination with aviation took root in my early teens, drawn in by the grandeur and beauty of aircraft. This interest paired well with my love for physics and math, steering me towards a pathway that eventually combined my academic interests with aviation.
How did you plan the steps to get into the career you wanted? Or how did you make a transition to a new career? Tell us about your career path.
My initial entry into the field of heat transfer materialized during my master’s program at Fresno State. It was during this period that I had the opportunity to join a lab renowned for its specialization in thermal management. The lab was a hub of innovation and practical exploration where theoretical knowledge met real world applications. With the guidance of accomplished professors and motivated peers, I started a deep dive into learning and hands-on experimentation.
During my master’s program, I initiated my professional journey with the Aerospace Facilities Group, a firm engaged in numerous projects for the US Air Force. They specialized in building abrasive blast booths, paint booths, dust collectors and various other equipment to support the US Air Force bases in paint removal tasks for their aircraft. Despite being a small company, the experience was rich and rewarding. Shortly after my joining, my immediate manager retired, positioning me as the primary point of contact for all engineering needs. This unexpected turn propelled me into a steep learning curve, which led to my absorbing a vast amount of knowledge within a few months. My core responsibilities included designing equipment, creating detailed drawings for fabricators, performing flow path analysis for cyclone separators and dust collectors, and sizing equipment as per customer specifications.
After my post- graduation, I transitioned to Ancra Aircraft, where my primary mission was to design and build radar cooling systems for fighter aircraft. During my time there, which spanned three years, I substantially expanded my expertise in heat transfer, which became a cornerstone of my engineering skills.
As 2020 unfolded, a desire for a career shift arose, steering my interest towards the electric vehicle domain. It was during this exploratory phase that I stumbled upon magniX, a company at the forefront of electric propulsion systems for aircraft. They were in search of a Mechanical Engineer for their Power Electronics team. The role seemed tailor-made for my skills and aspirations. I submitted my application online and was thrilled to receive an interview invitation within a week. The interview was centered around heat transfer fundamentals and the daily coordination of the mechanical engineering tasks, aligning with my accumulated experience and knowledge. The convergence of my experience and a well-timed opportunity at magniX marked the beginning of my current career path. Fortunately, the alignment between what I studied during my master’s and the work I embarked on ensured a smooth transition without any visa complications.
How did you get your first break?
Following my post-graduation, I wanted my next role to have deeper design and analysis work. It was during this time that I reached out to a friend who was working at Ancra Aircraft. Knowing my eagerness to delve deeper into design work, she graciously forwarded my resume to her manager. This connection led to an interview opportunity, where my experience at Aerospace Facilities group and the university lab proved to be a valuable asset. Consequently, I joined Ancra and over the next three years, I honed my skills and deepened my understanding in the heat transfer and fluid mechanics field, further developing my engineering capabilities.
What were some of the challenges you faced? How did you address them?
Challenge 1: One of the major challenges which I faced was in transitioning to life in the US when I went for my masters. My day-to-day operation took a sharp turn. Suddenly, I had to do all my daily tasks such as cooking, paying bills on time and managing finances all by myself without depending on my parents.
Challenge 2: The pace at which technology evolves in this field can be rapid. Keeping up with the latest developments in manufacturing, material, and simulation advancements, understanding their implications on your work, and integrating new solutions demand a continuous learning mindset.
Where do you work now? What problems do you solve?
I am currently employed at magniX, a pioneering firm dedicated to advancing electric propulsion systems for aircraft applications. The propulsion system consists of a large 650 kW electric motor and four 170 kW inverters that power it. This motor drives a propeller and the entire system works to replace the current turboprop engines on aircrafts. For the past 3.5 years, my role as a lead power electronics mechanical engineer has primarily involved leading the electronic packaging aspect of the inverter, with a special focus on thermal management. My duties span a variety of design facets including structural design, 3D modeling, validation testing, high voltage insulation system design, EMI mitigation, and providing assembly instructions.
What skills are required in your role? How did you acquire the skills?
The core of my responsibilities involves ensuring the inverters are meticulously designed and rigorously tested to withstand the harshest operational and environmental conditions encountered in flight. The nature of my daily tasks fluctuates in alignment with our quarterly objectives. At present, my attention is on the analysis required to create operating temperature predictions for our inverters as we gear up to dispatch our system to NASA’s Electric Aircraft Testbed (NEAT) facility. This unique facility offers a rare platform for testing high power equipment like ours under simulated high-altitude conditions, providing invaluable insights into the behavior and resilience of our propulsion system without having to undertake flight tests.
How does your work benefit society?
The societal benefit arising from our work lies primarily in two domains: enhanced affordability of air travel; and significant reduction in carbon emissions or, in some cases, achieving zero emissions.
Over the past five decades, aerospace engineers have tirelessly addressed the challenge of making air travel more economical and have achieved remarkable success. If we set aside the disruption caused by the COVID pandemic and rewind to 2019, it’s evident that air travel has become cheaper, safer, and faster than ever before. As engineers, it’s our duty to pick up the torch and strive for even greater affordability in flying. The technological innovation we’re engaged in holds promising keys to this goal given their potential for near zero fuel costs, increased efficiency, zero emission cost, and reduced maintenance costs when compared against conventional jet engines.
The groundbreaking technology we are developing stands to revolutionize the aviation sector in pivotal ways, thereby ushering in a new era of sustainability. This transition is not merely about cost-effectiveness but extends significantly to reducing the carbon footprint and noise pollution associated with air travel.
The forefront of our endeavors is marked by the ambition to drastically reduce carbon emissions and, in some scenarios, eliminate them. Unlike traditional propulsion systems, the electric propulsion technology we are working on is powered by electricity, which can be harnessed from renewable sources. This shift not only mitigates the release of harmful greenhouse gases but also substantially diminishes the noise pollution traditionally associated with aviation. The relatively quiet operation of electric engines contributes to a less intrusive and more environmentally harmonious interaction between air travel and surrounding communities.
Furthermore, the ripple effect of our innovations transcends the immediate aviation sector. By substantially lowering the barriers to air travel through cost reduction and contributing to global emission reduction goals. We are essentially widening the horizon of opportunities. With these lower costs, more individuals can afford to travel, encouraging cultural exchanges and strengthening economic interconnections globally. Moreover, the environmental responsibility reflected in our work aligns with broad societal values and global initiatives aimed at combating climate change and preserving our planet for future generations.
Tell us an example of a specific memorable work you did that is very close to you!
My most memorable times are during the 1st flights of new aircraft models retrofitted with our electric propulsion system. During my period at magniX, we have done four 1st flights on four different aircraft models. Watching the aircraft, equipped with the electric propulsion unit that we have poured our sweat and soul into, ascend gracefully into the skies was nothing short of magical. The thrill of witnessing our technology take flight, combined with the anticipation and eventual success of the test, is a feeling I will cherish forever.
Not only did these flight tests validate our team’s hard work and dedication, but it also reinforced my belief in the transformative power of sustainable aviation.
Your advice to students based on your experience?
The world of engineering and technology is vast and ever evolving. It’s essential to remain curious and hungry for knowledge. Don’t just accept things at face value, delve deeper, ask questions, and strive to understand the ‘why’ behind concepts. This curiosity will not only solidify your understanding but will also open doors to new ideas.
While creating cutting-edge solutions is commendable, real impact is made when your innovations are affordable to the masses. Always keep in mind that the true measure of success is not just pioneering technology, but in making sure that as many people as possible can benefit from it. The broader the reach of your solution, the more profound its impact on society.
Future Plans?
My immediate future plan revolves around a significant milestone for our propulsion system. We are actively working towards certifying our electric propulsion system to conform to the FAA’s Part 33 regulations for aircraft engines. With this certification, our system can be installed on aircrafts used for commercial operations with paying passengers. This step is pivotal for us, as it will demonstrate that our electric propulsion unit meets rigorous safety and performance standards set by aviation authorities. By achieving this certification, we will be reinforcing our commitment to delivering reliable and safe electric propulsion units for the aviation industry. It’s an exciting and challenging phase, and I am fully invested in ensuring its success. Beyond this, we are also exploring how to further innovate and refine our technologies to make electric aviation more affordable and efficient for all.