Forward looking Research and Development initiatives in Materials Science & Technology have laid the groundwork for swift progress seen in commercial-grade metal 3D printing and additive manufacturing practices in recent times.
Sastry Kandukuri, our next pathbreaker, currently works at DNV (Norway), supporting customers with subject matter expertise in the areas of additive and conventional manufacturing Materials/Process/ Facility/Design related qualification/ certification, training and Quality/code compliance.
Sastry talks to Shyam Krishnamurthy from The Interview Portal about his more than 20 years of experience as Global Materials Specialist helping customers through their journey of additive manufacturing adoption in Maritime, Oil & Gas, Mining and other heavy industries.
For students, it is important that you foster a highly critical mindset towards current technologies and challenges, and endeavour to find solutions while bearing social responsibility in mind.
Sastry, Your background?
Born and raised in a small village in the West Godavari district of Andhra Pradesh, my father worked as a teacher. For generations, no one in our family has ventured beyond the state, and I’m not aware of anyone in our village who pursued engineering education. I began schooling alongside my younger sister, quickly progressing through the curriculum to complete fifth standard despite officially being in third standard. Even at a young age, teachers remarked that I would one day become a scientist. During primary school, my interests encompassed geography, listening to the radio, reading newspapers, storybooks, and general knowledge texts, which helped me broaden my understanding of the world.
In high school, despite initially choosing to sit at the back of the class, possibly due to shyness or a fear of teacher scrutiny, my active participation and accurate responses led teachers to encourage me to sit at the front. They soon instructed me to refrain from answering first and instead wait until others failed to respond, significantly raising my sense of responsibility. To avoid embarrassment, I diligently prepared in advance to meet the teachers’ expectations. Our family couldn’t afford private tuition, so I relied on school and public libraries for information.
What did you do for graduation/post graduation?
I completed my undergraduate education (BTech) at the National Institute of Advanced Manufacturing Technology, formerly recognized as the National Institute of Foundry and Forge Technology. I chose this institute due to its unique dedication to a single industry sector, i.e. primary metal and machinery manufacturing.
Following my undergraduate studies, I gained three years of valuable work experience at Bharat Heavy Electricals Limited (BHEL) is an Indian central public sector undertaking in Haridwar, before embarking on my MTech. program in Materials Technology at IIT Madras.
During this time, I gained valuable practical experience in the production field while working in an industry. During this period, I realized my inclination towards research and development (R&D), which necessitated a Master’s degree. Consequently, I decided to leave my job at a public sector undertaking and pursue further studies.
Upon entering the post-graduate program with three years of practical experience and a solid foundation of theoretical knowledge acquired through extensive reading, I quickly caught the attention of senior professors. This academic journey proved to be deeply meaningful and fruitful, as it provided me with opportunities to apply my practical insights and theoretical understanding, contributing to a rich learning experience.
Can you share with us some of the key influences that led you to such an offbeat, unconventional, and unique career in research?
I never had a long-term career goal in mind. Still, various incidents and feedback from teachers, professors, and superiors made me realize that my strength lies in a deep understanding of subjects and unconventional problem solving approaches. Though I hadn’t meticulously planned my career trajectory, I can recount how it unfolded organically.
When contemplating my future career in engineering, many suggested studying electronics or computer science. However, I was curious about the least preferred option and its reasons. Metallurgy emerged as the least preferred option due to its intense theoretical nature and the vast industrial facilities required, making laboratory-scale experiments challenging in educational institutes. Despite the lack of glamorous career prospects, I saw potential in mastering this less-trodden path, believing that hidden treasures lie where few venture. Metallurgy has since proven to be a rewarding and fulfilling journey.
Before graduation, I lacked significant influencers, but encounters during industrial training at places like Tata Steel, Tata Motors, and Indira Gandhi Centre for Atomic Research, as well as interactions at IIT Madras and my initial job at a public sector undertaking, introduced me to deep-tech experts in materials engineering. Authors like Robert E. Reed-Hill, through books like “Physical Metallurgy,” also left a profound impact on me.
While attending conferences in Materials Science and Engineering, I initially didn’t find much influence on my career choice or progression.
During post-graduation, I faced a dilemma: pursue a software industry job, a hardcore industry job, or a PhD route. A campus interview for a software job ended with the HR manager advising against it due to my evident passion for metallurgy. Meanwhile, the prospect of a PhD, marked by the appearance and demeanor of current scholars, didn’t appeal to me. Opting for an industry job in metallurgy led me to work at the construction site of the Jamnagar refinery, offering a lifetime experience due to its sheer scale.
After my MTech, I spent approximately one year working at Reliance Petroleum in Jamnagar.
Later, I made a transition to The Advanced Materials and Processes Research Institute (AMPRI) in Bhopal, formerly known as the Regional Research Laboratory (RRL). AMPRI is a government research institute operating under the Council of Scientific and Industrial Research (CSIR), New Delhi.
Upon joining AMPRI, I was chosen by the organization and awarded sponsorship for a two-year full-time postgraduate program in Computer Science & Management at Barkatullah University (formerly known as the University of Bhopal), a public university located in Bhopal, Madhya Pradesh, India. This program, crafted with a flexible working arrangement, aimed to nurture homegrown IT architects with a scientific background, empowering them to contribute significantly to the organization’s digital transformation initiatives.
Despite pressure to pursue a PhD, I remained determined to find the right opportunity for fast-paced research. The pivotal moment arrived with an invitation from the Belgian Government for a research fellowship, introducing me to 3D Printing.
Tell us about your career path
During my initial job/internship, management tasked me with investigating quality issues in a factory’s continuous production process. This experience honed my skills in quality assurance audits and third-party certification—a competency I’ve nurtured over the past 25 years. Despite the prestige associated with the three different jobs I’ve held—ranging from the public sector to central government positions—I often found myself unsatisfied and urged by colleagues to seek a role that fully leveraged my skills. Consequently, I continually sought new opportunities or pursued higher degrees to explore my potential further.
While interning at the Indira Gandhi Centre for Atomic Research (IGCAR), I aspired to be in a career in R&D, but hesitated to commit to a mandatory PhD pathway. However, an unexpected research fellowship offered by the Belgian government exposed me to R&D in Belgium, eventually leading to the completion of my PhD. There, I gained insights into collaborative efforts between companies, educational institutes, and R&D centers, shaping my subsequent career trajectory.
In the early 2000s, industrial 3D printers—particularly those specializing in metal—were predominantly utilized within academic and research and development contexts. The technology, being relatively nascent, remained financially out of reach for most consumers. Furthermore, commercially available printers were scarce, and the availability of essential materials like powders was limited. Notably, there was a notable absence of optimized process parameters tailored to different materials.
However, forward-thinking research and development initiatives in Materials Science & Technology during this era were pivotal. These efforts focused on establishing correlations between structure, process, and property, examining laser-material interactions, understanding sintering dynamics, and characterizing powder properties. These endeavors laid the groundwork for the swift progress seen in commercial-grade metal 3D printing and additive manufacturing in subsequent years.
While incremental advancements and innovations in 3D printing were witnessed throughout the early 2000s, a significant shift occurred in 2005. This marked the expiration of several early patents, opening avenues for inventors and entrepreneurs to seize opportunities and drive the technology towards widespread adoption.
Can you explain the objective of your research at KU Leuven?
As for my doctoral studies at KU Leuven, they were part of a European Union-funded project under ‘The Sixth Framework Programme (FP6).’ This initiative aimed to advance research, technological development, and demonstration (RTD) activities from 2002 to 2006. With a substantial budget, FP6 focused on fostering science, research, and innovation within the EU, contributing to the establishment of the European Research Area (ERA).
Our project, titled “Field Assisted Sintering Technology (FAST),” led by KU Leuven’s R&D division at MTM, comprised a consortium of partners from various EU countries, ranging from start-ups to established industrial entities and research laboratories.
The technical objective of our project was to employ FAST sintering techniques to manufacture fully dense net-shaped advanced aluminum alloy compacts for automobile engine applications. Our scientific goal was to deepen our understanding of the relationship between field-assisted sintering parameters and the sintering behavior of advanced aluminum alloys.
One noteworthy challenge raised by a partner involved in designing automobile racing engines highlighted a materials challenge. They pointed out that traditional casting-based aluminum alloys had reached saturation limits. Therefore, improving mechanical properties through new technologies could reduce weight, particularly in moving engine components, offering acceleration benefits. Hence, our goal was to explore powder-based technology over traditional casting routes to develop enhanced materials.
My role in the project encompassed conducting research on producing and characterizing metal powders, investigating sintering mechanisms, collaborating with machine manufacturers on technology development, and evaluating the performance of consolidated materials.
The primary focus of my research was to explore the feasibility of producing fully dense aluminum alloy powder compacts from rapidly solidified powders/flakes using FAST technology, targeting potential applications in automobile engine components. The main challenge lay in achieving full density due to the inherent difficulties in sintering aluminum, attributed to tenacious oxide films on particle surfaces and entrapped gases hindering densification.
Upon concluding the research, we demonstrated the consolidation of mechanically milled nanostructured Al-Si-Fe-X powder into fully dense compacts using FAST technology, yielding materials with significantly superior mechanical properties compared to traditionally produced counterparts. A contributing factor to this success was the ability to produce materials with a nanostructure featuring grain sizes of 55-70 nm.
Our research has played a significant role in establishing correlations between the structure, process, and properties of specific materials, comprehending sintering dynamics, and advancing the production and characterization of powders.
Just as my research for my Master’s thesis earned me the esteemed National-level “Innovative Potential Award” in India, my doctoral thesis also garnered recognition, this time in Europe. Specifically, my PhD thesis received the distinguished Best PhD Thesis Award for the years 2007-2009, sponsored by Höganäs AB in the biennial Europe-wide EPMA Thesis competition. I received this award from EPMA President Mr. Ingo Cremer during the 17th annual Euro PM2008 Congress & Exhibition’s plenary session held in Mannheim, Germany. These awards confirm my belief that dedication and passion matter more than the specific field of study, whether it’s computer science or metallurgy. What truly matters is the potential to make an impact wherever you are.
A few months prior to defending my thesis, I had a fortuitous encounter with a visiting scientist from Canada during his visit to KU Leuven. Intrigued by the potential of my research to revolutionize certain industrial applications, an offer was extended to me to relocate to Canada. During that period, Daimler Chrysler was making substantial investments of $500 million in automotive research and development facilities at the University of Windsor. As part of this initiative, the Centre for Automotive Research and Education (CARE) was established to maximize the benefits stemming from Daimler Chrysler’s new R&D endeavors.
Later that year, I relocated to Canada and commenced employment at CARE. Within this role, my main emphasis, alongside fellow researchers, centered on advancing and refining the emerging 3D Printing technology called Cold Spray technology. This innovative method played a crucial role in rejuvenating discarded large engine castings by rectifying defects, ultimately revitalizing them to a pristine condition. Our research efforts weren’t confined solely to automotive applications; we also delved into devising 3D Printing solutions for nuclear and defense sectors.
Despite transitioning to R&D roles during stints in Belgium and Canada, my move to Norway 18 years ago saw a shift towards standards development and ensuring compliance—a role that still involves elements of R&D and innovation, keeping me engaged with technological frontiers. Over the past decade, I’ve been deeply involved in 3D Printing, a field I first explored 20 years ago. This specialization has provided immense job satisfaction, industry influence, and opportunities for meaningful contributions, earning recognition for my work. My recent relocation to Singapore, from 2017-2021, to establish and lead the Global AM Technology Centre of Excellence further enriched my journey, facilitating interactions with fascinating individuals across various industries.
How did you get your first break?
During my school years, I made a firm decision to pursue a career in very large enterprises, particularly in public sector undertakings (PSUs). I recognized that the best pathway to achieve this goal was to study at a premier institute and secure a campus placement. Thanks to my academic achievements, I successfully secured this coveted opportunity soon after my graduation. This trend continued even after completing my Masters, allowing me to consistently pursue my career aspirations within the realm of large enterprises.
When I relocated to Belgium, pursuing a PhD was not my initial intention. The journey began during my tenure at AMPRI (formerly RRL) in Bhopal when, based on certain internal criteria, I was nominated by our organization for a Belgian Government fellowship in Technical Metallurgy. This fellowship encompassed a year-long assignment in Belgium. After an evaluation of my research profile and a subsequent interview, I was chosen and invited by a host research institute in Belgium. Despite the rigorous selection process, I didn’t perceive it as such due to the strong interest displayed by the host institute in my accomplishments. Consequently, with the collaboration of the Ministry of HRD India and the Belgian Embassy in India, arrangements were made for my relocation to Belgium.
During this fellowship, my focus was on conducting research that benefited both India and Belgium. I collaborated with numerous researchers involved in laser material interactions, the development of 3D printing machines and technology, powder production processes, and conducted research in these domains.
Upon returning to India to resume my position at AMPRI, I received a regular job offer from the Belgian host research institute to relocate back and work as a Research Scientist in their research projects. Even then, pursuing a PhD was not on my radar as I was reluctant to leave my research position and become a full-time student to fulfill the academic requirements for doctoral studies.
However, upon my second relocation to Belgium, I was offered the opportunity to enroll at KU Leuven as a PhD candidate with a full waiver of academic courses as a special case, based on my research merits and dual master’s degrees, among other factors. This allowed me to register for a PhD and focus on core research and complete it in a significantly shorter timeframe compared to full-time regular students, despite working as a full-time researcher.
What were some of the challenges you faced? How did you address them?
Throughout my extensive career, I encountered numerous challenges that tested my resilience and determination.
The first challenge involved navigating negative or skeptical individuals within various systems. Instead of being deterred, I embraced these encounters as opportunities for growth. I endeavored to collaborate with them, impress them with my work, and ultimately establish friendly relations.
The second challenge revolved around maintaining a leading edge in my field while balancing numerous responsibilities. This required immense effort, sacrifices, dedication, and often led to sleepless nights, mainly when engaged in cutting-edge research or technology development. However, I tackled this challenge through self-motivation and the unwavering support of my family and friends, who encouraged me to pursue my passion and profession.
Lastly, the challenge of living and working far from family, childhood friends, native culture, and language presented its own set of difficulties. While not a significant obstacle, it necessitated making compromises and prioritizing between career and personal life. Fortunately, the advent of the internet has facilitated access to familiar comforts such as movies and newspapers in our native language, helping to bridge the gap between distance and familiarity.
Where do you work now? What problems do you solve?
I currently work at DNV in Norway
During my initial years at DNV in Norway, my primary focus was on conventional manufacturing technologies, such as developing material rules for maritime applications and overseeing manufacturer qualifications. DNV maintains an approved manufacturing base of approximately 2000 manufacturers across more than 50 countries worldwide. DNV’s approval of manufacturers (AoM) confirms compliance with international standards, regulations, or recognized DNV rules, providing companies with evidence of high quality and safety standards. I managed this service portfolio from our head office.
In mid-2012, during the Obama Administration, the “We Can’t Wait” initiative was announced, which included the launch of a pilot institute as a proof-of-concept for the National Network of Manufacturing Innovation (NNMI). The National Additive Manufacturing Innovation Institute (NAMII) was established to support new additive manufacturing technologies and products, aiming to become a global center of excellence for additive manufacturing.
Following this announcement, additive manufacturing technology garnered significant attention from industrial sectors, particularly from key customers involved in maritime, offshore, and oil & gas industries. Many of these customers began contacting us to understand the rules and standards applicable to implementing 3D printing as an alternative manufacturing technology for their assets.
Motivated by these inquiries, in 2014-15, I applied for internal funding to lead a project focusing on materials certification/qualification pathways for additive manufacturing (AM)/3D printing. This initiative resulted in an internal report titled ‘Pilot Study on Materials Certification/Qualification Pathway for Additive Manufacturing (AM)/3D Printing Route.’ The report emphasized how AM has the potential to revolutionize product design and local manufacturing through a distributed network of AM printers, thereby reducing lead times and transportation costs. It also addressed challenges, opportunities, and a roadmap for qualification and certification of AM processes and components, leading to the initiation of several internal and external projects.
My work drew the attention of Singapore government authorities through interactions with our local office, leading to an invitation to Singapore to engage with the AM ecosystem. Subsequently, in 2017, I relocated to Singapore and established the DNV Global Additive Manufacturing Technology Centre of Excellence (AM CoE), sponsored by the Economic Development Board of Singapore. Leading DNV’s global AM innovation programs, my team and I made significant contributions to the advancement of additive manufacturing, leaving a lasting impact on the industrial and scientific communities.
Returning to Norway in 2021, I continued to work full-time on AM technology. Over the years, I have closely collaborated with customers, providing expertise in additive manufacturing materials, processes, facilities, design-related qualifications/certifications, training, and quality/code compliance. I have assisted various industries, including maritime, oil & gas, mining, and heavy industries, in adopting additive manufacturing, building trust in AM products.
My most significant contribution to the AM/3D printing field has been in developing standards. I am the lead author of several DNV standards and service documents in the field of AM. Additionally, I collaborate closely with various standards organizations, including ISO, ASTM, API, and ASME. Notable contributions to AM standards development include active involvement within the Singapore Manufacturing Federation and Singapore Military AM standards working group. Recently, my exceptional contributions to Singapore’s AM Standardization Programme earned me the Enterprise SG-SSC/SAC Commendation Award in 2022.
I am currently immersed in the field of technology development, with a particular focus on 3D Printing/Additive Manufacturing. In this capacity, I tackle various challenges, primarily centered around building trust in new technologies. These technologies hold significant potential for enhancing supply chain resilience, promoting sustainable manufacturing practices, and replacing physical inventories with digital equivalents. Additionally, I am actively involved in standards development initiatives aimed at supporting these objectives. By addressing these challenges, I strive to contribute to the advancement and widespread adoption of innovative technologies in various industries.
What skills are needed for your role? How did you acquire the skills?
I see three crucial skills as essential in my line of work:
1. In-depth knowledge: I have acquired this through my academic background, continuous reading of technical and scientific journals, and staying updated on technological developments.
2. Presentation/influencing skills: Given the scale of development and transformation technologies I work with, it’s crucial to influence various stakeholders in government, industry, and society to garner consensus, funding support, and collaboration. I honed this skill through previous teaching experiences and inherent abilities.
3. Networking and group work: My work often involves networking and collaborating with diverse groups, building trust with individuals I’ve never met before. Establishing a solid network of individuals who have benefited from my work enhances this process positively.
What’s a typical day like?
A typical day for me unfolds in two main ways:
1. While I’m in the office: I engage in numerous online and in-person meetings throughout the day with minimal breaks. These meetings typically revolve around ongoing projects, where I advise clients on compliance certification, provide technical guidance to solve any issues they may encounter, or clarify standards.
2. While traveling: I frequently travel to meet clients in person, attend conferences and workshops, or conduct compliance audits at client facilities. During these trips, I focus primarily on client meetings, ensuring productive discussions and progress.
I find immense satisfaction in contributing to and advising clients with my knowledge and subject matter expertise. Additionally, I enjoy visiting new places, meeting new people, and influencing them positively with my expertise.
How does your work benefit society?
Working with an organization with a societal focus since its establishment in 1864 brings me immense satisfaction. Our core purpose at DNV is to safeguard life, property, and the environment, with a vision to be a trusted voice in addressing global transformations. In my daily role, I contribute to this vision by playing a pivotal role in advancing renewable energy projects and promoting sustainable practices. By doing so, I actively participate in accelerating the transition to cleaner energy sources and cultivating a greener future. In summary, our work at DNV benefits society by enhancing safety, reliability, sustainability, and innovation across various sectors.
Tell us an example of a specific memorable work you did that is very close to you!
I have numerous memorable technical achievements, but I’ll begin with a general one. Upon joining my current employer 17 years ago, I was tasked with teaching a basic course in Materials Technology to colleagues without a materials background. Initially, I doubted my ability to convey complex concepts effectively, given my knowledge at the PhD and postdoctoral levels. However, I found immense satisfaction in delivering this course to over 3000 colleagues worldwide through two-day classroom sessions (comprising around 125 sessions). The overwhelmingly positive feedback I received indicated that I had successfully made one of the toughest and most complex subjects enjoyable and memorable for them, enabling them to excel in their roles. Many of these colleagues still reach out to me, recalling what they learned and how they continue to apply it, which brings me immense pleasure knowing that I’ve been able to help so many colleagues.
Another significant achievement occurred during my master’s degree. After spending several years in industrial environments, I returned to academia to pursue my master’s degree amidst India’s sanctions by the West, which emphasized indigenous technology development. Some senior Professors approached me to work on a material development and testing project, presenting a unique challenge as there were no available references. This project pertained to space technology, a domain limited to only five countries globally, with no publicly accessible information for us to reference. I developed innovative testing capabilities through months of dedicated work and successfully completed the project within six months. My professors’ team deemed it worthy of the equivalent of several years of PhD-level work. Subsequently, this project was nominated for a national Innovative Potential Award and reviewed by Dr. APJ Abdul Kalam, ultimately winning the award. Receiving this accolade from then-Prime Minister Shri Atal Bihari Vajpayee was an incredibly memorable moment that has kept me motivated to this day.
Your advice to students based on your experience?
My advice to students is to prioritize learning fundamentals thoroughly. Cultivate a genuine interest in acquiring knowledge and delve deeply into the subject matter. If possible, strive to become a subject matter expert in one or more topics. Foster a highly critical mindset towards current technologies and challenges and endeavor to find solutions while bearing social responsibility in mind. By following these principles, students can not only excel academically but also contribute meaningfully to society and the advancement of technology.
Future Plans?
I haven’t formulated any specific plans yet, but I envision continuing my work in the field of technology development. Additionally, I anticipate devoting time to mentoring both aspiring students and entrepreneurs who aspire to foster innovation through research or its practical implementation.
Here is access to my research :
https://www.researchgate.net/profile/Sastry-Kandukuri
Some Articles by me:
Additive Manufacturing for oil, gas and maritime: An evaluation of capabilities and potential
New industry standards drawn up for 3D printing
Additive manufacturing to disrupt oil and gas industry
Can ‘printed’ parts make oil and gas operations smarter and greener?