Whether it is aircrafts that transport us, or power plants that address our critical energy needs, their structural integrity ensures safe and reliable performance under various scenarios .
Onkar Patil, our next pathbreaker, Structural Analyst at Holtec International (New Jersey), specializes in the design and development of storage and transport casks for spent nuclear fuel.
Onkar talks to Shyam Krishnamurthy from The Interview Portal about starting his career as an FE (Finite Element) Analyst at Bajaj Auto which laid the foundation for his professional journey in structural durability analyses of components and assemblies.
For students, you can build a career in sports, culture, art, music, or any other field, the key is consistent self-improvement, self-calibration and no comparison with others.
Onkar, can you share your background with our young readers?
Hey there, I’m Onkar Ravindra Patil. I was born in Latur, a city in the Marathwada region of Maharashtra. My father served as a Judge, and my mother is a homemaker. I’m their only child. Because of my father’s government service, we moved every three years to different parts of Maharashtra. That meant new schools, new teachers, new cultures, and new friend circles—every few years. Looking back, I now see how that constant change played a big role in shaping me. It exposed me to a wide variety of experiences; technical and non-technical activities, diverse cultural events, different ways of learning and living. These experiences planted the seeds of my interests in academics, music, and art. In school, I naturally gravitated toward the front benches. Slowly but steadily, my interest in academics deepened. It’s only now, after 15–20 years, that I truly realize how important that early engagement was in shaping a career in academics. The frequent school changes were challenging, but I stayed focused and kept moving forward. While academics took the front seat, I also explored art and music, not with the same intensity, but consistently. And today, I find joy in going back to those creative tools, sharpening them, and making time for what I love. One thing that really helped me in academics was my habit of daily revision. I made sure to go over everything taught in class each day. Thanks to that, I never had to pull all-nighters before exams. As a child, I was curious about many fields, space, engineering, medicine, and more. That curiosity drove me to perform well, and I ended up topping my 10th board exams, which opened a wide range of opportunities for me.
What did you do for graduation/post-graduation?
As I mentioned earlier, my versatile interests naturally led me to choose the Science stream for my 11th and 12th. I opted for the PCMB (Physics, Chemistry, Mathematics, Biology) group and continued with the same disciplined study strategy I had followed before. Without leaning too heavily toward either field, I prepared seriously for both engineering and medical entrances, appearing for both JEE and NEET. At the same time, I didn’t sideline my board exams. I gave them equal importance and managed to earn rank 1 in my college and divisional board during the HSC board exams, while also securing strong merit scores in both JEE and NEET. When the results came out, I found myself at a crucial crossroads, admitted to both a Government Medical College and a Government Engineering College. This is where making the right choice of stream and college becomes vital. And trust me, I’ve experienced the importance of that decision time and again, even now. The “college name tag” does hold weight—not everything, but certainly something. After careful thought, I chose Visvesvaraya National Institute of Technology (VNIT), Nagpur for my graduation. After going to Nagpur, I believe I was the only one in my circle who hadn’t- taken JEE Advanced, broke my heart for IIT and came to NIT. Securing a seat at an NIT itself was a big achievement for me. I was allotted to Chemical Engineering, but I had done my homework. I knew there was an option to change branches after the first year. Motivated by that goal, I focused on scoring well in my first year. With a strong GPA, I made it to the top of the list and successfully switched to Mechanical Engineering, my preferred branch. Now, I was part of a vibrant group of 100 bright mechanical minds. It was a new challenge, but I believed in myself and kept moving forward; slowly, steadily, and with purpose.
After my BTech, I worked for three years at Bajaj Auto Ltd. While working, I decided to dive deeper into the technical domain and started preparing for the master’s abroad. My intention to go abroad was to explore new regions, new educational systems, and new industries. Thus, I moved to the U.S. to pursue my master’s. I joined the University of Washington, Seattle, for a Master of Science in Mechanical Engineering. I was focusing on aerospace product design, analysis, testing, and development as my master’s project. My master’s project even led to a patent, which was a major milestone in my journey.
What were some of the key influences that led you to such an offbeat, unconventional, and unique career in core mechanical engineering ?
While pursuing my academics and exploring my interests, I had the opportunity to meet and learn from many inspiring speakers and mentors. One of the most memorable moments was when I got the chance to shake hands with my role model, Dr. APJ Abdul Kalam, who visited our college as a guest lecturer during my second year.
In my third year, I was honored to be selected as a student mentor by my department, where I was entrusted with guiding 15 first-year students. I firmly believe that having a mentor is crucial in everyone’s journey. Whether the challenges are academic, non-academic, technical, non-technical, or even cultural, there’s almost always someone who has faced them before. With the right mentors, you can learn from their experiences instead of starting from scratch. Why do you spend time and money reinventing the wheel when you can build upon what’s already done? Learn, adapt, customize, and then take on new challenges.
Personally, I learned many of these lessons through trial and error, by experimenting, failing, and trying again. But I didn’t want my juniors to go through the same delays and confusion. So, I made it a point to share these insights with them, hoping to make their journey smoother. All of these experiences have played a vital role in shaping my path as a student, learner, mentor, and guide in both academic and technical domains. Along with this, I helped and now also help them in all the other aspects (tech, non-tech, cult, emotional, career-choosing, etc.).
How did you plan the steps to get into the career you wanted?
While actively working on all fronts in my academics, I found my interest steadily growing in the field of design and analysis. During the second year of my engineering studies, I applied for and was selected for a summer research project at VNIT, Nagpur in the domain of Computational Fluid Dynamics (CFD). It was during this project that I first encountered ANSYS, a Finite Element Method (FEM) software, which sparked a deep curiosity in me. I began exploring other FEM tools as well, which further deepened my interest. In the third year, I got the opportunity to intern at Bhabha Atomic Research Centre (BARC), Mumbai. Interestingly, ANSYS was again a part of my work there, reinforcing my inclination toward simulation and analysis. These experiences laid the foundational stones of my technical career.
Interning at BARC was another enriching experience in my journey, as it was the first time I got to apply my core engineering knowledge in an industrial setting. It gave me the opportunity to bridge theory with real-world applications and truly understand the practical value of foundational skills. I was involved in a project focused on the analysis and testing of a device known as the Spiral Elevator, or Hull Rinser. This machine is used in the processing of nuclear waste tubes. Essentially, the tubes are fed into the device, which contains a rinsing liquid. The system is agitated using high-power motors to effectively rinse the tubes and remove residual nuclear sediments, preparing them for safe disposal. My key responsibility was to assess the structural strength and durability of the Hull Rinser. I utilized ANSYS to conduct various types of finite element analyses, including strength, durability, and modal analysis to evaluate potential resonance issues. I also analyzed force transmission to the ground and assessed the overall structural stability of the system. Through this project, I was able to answer critical questions regarding the long-term reliability and safety of the device under operational conditions.
This internship not only deepened my understanding of simulation and testing but also strengthened my confidence in solving complex engineering problems in high-stakes environments.
In the final year of my BTech, I was selected by Bajaj Auto, Pune through campus recruitment. I joined them after graduation and began my professional journey.
Starting my career as an FE Analyst at Bajaj Auto was truly a curtain-raiser. It laid the foundation for my professional journey. My approach was centered around learning, delivering, and growing, both technically and personally. In this role, I was responsible for performing a wide range of finite element (FE) analyses, including static, dynamic, linear, nonlinear, modal, PSD, and durability simulations. These analyses were carried out across various components like engines, chassis, and other critical parts; spanning two-wheelers, three-wheelers, four-wheelers, and even field-failed components that required root-cause investigation. This was my day-to-day work, bread and butter.
Along with it, to improve efficiency and minimize manual workload, I developed automation tools using Python and Microsoft Excel VBA. These tools streamlined FEA post-processing and data analysis, making our workflows faster and more reliable. Being naturally inclined toward hands-on work too, I went beyond the standard responsibilities of my role. Despite the presence of a dedicated testing team, I personally led and executed tasks such as strain gauging, non-destructive testing (NDT), shaker tests, and torture tests. I was involved in both the design and execution phases of these tests, followed by in-depth data analysis using tools like nCODE and Excel to interpret stress-strain behavior and predict durability.
In addition to my technical contributions, I took on mentorship and leadership responsibilities after two years of my experience in the department; training four new graduate trainees and managing general administrative tasks for our group. This experience gave me a well-rounded perspective on both the technical and organizational aspects of engineering.
This is where curiosity and alignment of interest with one’s job role become critical. If your interests don’t align with your role, it’s time to find a platform that does. Thankfully, at Bajaj, I was able to align my passion with my work, delving deeper into design, FEM analysis, hands-on testing, and validation. My interest continued to grow as I gained real-world experience. While staying actively engaged in my job, I also made a conscious effort to explore emerging trends and developments; both within my domain and more broadly. This habit helped me stay aligned with evolving technologies and industry shifts. Building a career isn’t like flipping a switch; you don’t instantly step into a new area of expertise or experience. It demands patience, adaptability, and continuous learning; values I embraced throughout my tenure at Bajaj.
Can you tell us about your career path after Bajaj and especially about your MS program?
Dr. Kalam has always been my motivation and idol, and my passion for space and space science has always been close to my heart. In fact, when I applied for my MS in the United States, I was accepted into both the MS in Mechanical Engineering (MSME) and the MS in Aeronautics and Astronautics (MSAA) programs at the University of Washington, Seattle. However, due to the many restrictions in the aerospace field in the US; especially regarding jobs, security clearances, and other factors, I decided to pursue the MSME program. That said, my interest in aerospace and astronautics remained strong within me.
In that spirit, I was fortunate to be selected for a project focused on aerospace product development. Let me briefly explain this project: astronauts on long spaceflights often face issues related to microgravity, which can reduce blood flow from the heart to the brain. This can cause fainting, blurry vision, and even unconsciousness. Research has shown that massaging the internal jugular vein (IJV) in the neck can help alleviate these problems. With this in mind, we set out to design a belt that could be worn around the neck. The belt had rollers powered by a battery, which would massage the veins of the neck.
This project was a collaboration between the UW Department of Mechanical Engineering and UW Medicine. Together, we designed, analyzed, manufactured, and tested the prototype. For testing, we created a test bench that simulated human anatomy. This bench included a skull (water reservoir), tubes (veins), a silicone neck (representing the human neck), a small pump (representing the heart), and pressure and flow sensors for data acquisition. Based on the data we collected; we made modifications to the prototype.
Finally, we conducted human trials at the UW Medical facility at Harborview Medical Center in Seattle. I am proud to say that I was the primary subject on whom the trials were conducted. The results were very promising, and eventually, we filed a patent for the research we conducted.
Regarding my experience in the U.S., after completing my master’s, I entered the American workforce by leveraging my prior experience at Bajaj to join Lucid Motors as a Finite Element Analyst in the automotive sector.
I was primarily responsible for developing load cases and conducting structural durability analyses for components and assemblies across various Lucid vehicles; particularly closures such as hoods, doors, and liftgates; using finite element (FE) software. I performed structural gauge and free-size optimization, which led to a 10% weight reduction in closures. Additionally, I utilized voxel-based topology optimization with Optistruct to define optimal load paths for the vehicle body and multiple subsystems. As the coordinator for the initial vehicle concept analysis, I ensured compliance with durability and crash requirements through multidisciplinary optimization. I was also involved in full-vehicle model building for crash simulations. Bringing my field engineering mindset to the role, I developed innovative test methods and setups and conducted a wide range of physical tests on closures to validate and correlate with FE simulation results.
Lucid is fully electric, while Bajaj Auto is powered by fuel. The main difference between the two lies in their power source, and from that, many other aspects of the vehicle’s design and operation come into play. However, the core principles of design, analysis, and testing remain consistent across all domains. This is something I always advise: sticking firmly to the fundamentals and then adapting as needed will help you thrive in any industry transformation. This is especially true in the context of the upcoming era of Artificial Intelligence and Machine Learning. To be ready for the changes that lie ahead, it’s crucial to have a strong and solid foundation in the basics. These fundamentals will serve as your anchor as new technologies and innovations emerge.
I then briefly explored opportunities in the solar energy industry and am currently working in the nuclear energy sector at Holtec International, New Jersey.
Across all these roles and industries, the core of my work has remained consistent; performing analysis, optimization, design modifications, and test validations. However, experiencing multiple sectors has given me a broader perspective and solidified the foundation of my career, layer by layer.
How did you get your first break?
My first break came just after I completed my post-graduation. I was passionate about applying my technical knowledge to real-world challenges, and I started exploring roles that aligned with my interest in sustainable energy. Through LinkedIn and connecting with people, I got connected with someone working at my first US company, and after a few follow-ups and extensive interviews, they gave me the opportunity to work as an analyst. That experience not only gave me a real time feeling of the industry but also solidified my belief that I was on the right path. Looking back, it was that one opportunity that really set the tone for everything that followed.
Although this is just one example from my career journey, such moments occur often; and sometimes when you least expect them. The key lies in recognizing them and seizing the opportunity. Opportunities, like birds, sing in the east and sing in the west you simply need to know how to listen. And sometimes, that’s all it takes to get your break.
What were some of the challenges you faced? How did you address them?
Challenge 1: The challenges were many. Securing a role in a good company is not a simple start-to-finish task. It’s a journey that demands time, patience, determination, and a mindset focused on continuous learning and improvement. In fact, just getting a call for an interview can consume almost 50% of your energy. The remaining effort goes into the interview process itself and everything that comes along with it. That initial hurdle, getting noticed and shortlisted, was a major challenge in itself.
Challenge 2: The next step brings its own set of tests. You need to be prepared for anything, “expect the unexpected!” Submitting a resume and hoping it speaks for you isn’t enough. You must be ready to face questions that may or may not lie within your comfort zone. This phase taught me a crucial lesson: the world doesn’t judge you solely on what you know. It also challenges you with what you don’t know. So, the only way forward is to strive for excellence in your area of expertise, while maintaining a learner’s mindset for everything outside of it. That approach has helped me navigate and overcome these challenges.
Where do you work now? What problems do you solve?
Currently, I am working as a Structural Analyst at Holtec International, based in Camden, New Jersey, USA. Holtec is a globally recognized leader in the nuclear energy sector, specializing in the design and development of storage and transport casks for spent nuclear fuel. In addition, the company is active in the development of Heat Transfer Equipment and Services, Nuclear Plant Decommissioning, Civil Construction, and pioneering technologies like the SMR-300 small modular reactor and Green Boiler systems.
What skills are required in your role? How did you acquire the skills?
In my role, I am responsible for conducting structural durability analyses of components and assemblies used in nuclear fuel storage and transportation systems. These analyses are performed under a variety of load cases using Finite Element Analysis (FEA) tools, ensuring full compliance with United States Nuclear Regulatory Commission (US NRC) and ASME guidelines. I also prepare detailed calculation packages to evaluate the structural performance and integrity of components used in the construction and decommissioning of nuclear power facilities. The foundation for this role lies in the first principles of mechanical engineering, which I developed during my undergraduate and postgraduate education. My software proficiency; particularly in FEM tools like ANSYS; has evolved organically, starting from my internship experiences and deepening through hands-on industry roles over the years. Given the technical nature of this field, I never view my journey as complete or saturated. Instead, I actively seek new knowledge, tools, and approaches to improve the quality and efficiency of my work. This mindset keeps me curious and innovative.
What’s a typical day like?
A typical day begins with team and project follow-up meetings, followed by collaboration with design teams, project managers, and technical leads, to gathering the necessary data for analysis. While routine tasks are part of the job, I make it a point to dedicate 30–60 minutes daily to exploring new technologies, industry trends, and innovative methods to enhance productivity and learning.
What is it you love about this job?
As I’ve said before, alignment of interest with one’s job role is essential. It directly influences your mindset and overall satisfaction. When your passion aligns with your profession, every day feels fulfilling. For me, mechanical engineering, particularly in design, analysis, and test validation has always been more than a job. It’s a field I’ve grown in and continue to enjoy deeply. Encountering that same passion in my current work environment is not just rewarding. It’s energizing. And that’s the whole thing I simply love about my job.
How does your work benefit society?
The guiding motto of my journey has always been simple yet profound: “Leveraging my technical skills and abilities in the service of mankind.”
With this vision in mind, I chose engineering as my path and dedicated myself wholeheartedly to it, completing my graduation, post-graduation, and continuously expanding my knowledge in the technical realm. Throughout this journey, I’ve held tightly to that core principle, ensuring that I never stray too far from it. Of course, not every single task or project we undertake may have a direct and visible impact on society. But I firmly believe that every step we take should, in some way, lead us toward the betterment of humanity. That belief has stayed with me and will continue to guide me in the future.
Now, as far as my current work is concerned, in my role as an analyst, I focus on analyzing structures and components intended for nuclear power plants. As the world gradually runs out of conventional fuels, the shift toward non-conventional energy has become not just important, but essential. Clean, sustainable energy generation has the potential to transform society in countless ways. And while my role may be a small part of that larger transition, I take great pride in contributing to a cause that holds such immense value for our collective future.
Tell us an example of a specific memorable work you did that is very close to you!
During the third year of my BTech, I had the opportunity to serve as a student mentor, responsible for guiding 15 first-year students. As a mentor, my role extended beyond academics, it included supporting them emotionally and socially as well. Interestingly, most of the issues I dealt with were non-academic. One particular case that still stands out to me involved a mentee who was struggling deeply with homesickness. Naturally introverted and shy, he found it hard to connect with others. He lived a very closed life, restricted to his “apartment and the department” building. This isolation began to affect not just his academics, but also his mental well-being.
For me, still a student myself, this was a real challenge. But one I felt compelled to take on. I started by inviting him to spend time with me during breaks or after classes. Slowly, I introduced him to my friends and encouraged him to interact more freely. At first, he was hesitant and even awkward. But something shifted when he noticed that his batchmates were surprised and even impressed that he was hanging out with seniors. That gave him confidence. Over time, I saw a transformation in him. His anxiety and self-consciousness began to fade, and he eventually formed his own circle of friends. From there, he started to embrace college life and truly enjoy his engineering journey; not just academically, but socially too.
Of course, things were challenging, especially in the beginning. Taking that first step was the hardest part. But I’ve learned that when you break down a big challenge into smaller, manageable steps and keep moving forward, you inevitably move in the right direction. Beyond academics, experiences like these give me a deep sense of fulfillment. There’s a unique kind of inner peace and joy that comes from making a real difference in someone’s life and that feeling is truly priceless!
Your advice to students based on your experience?
I strongly believe that discovering your passion early in life gives you a head start on the journey to excellence. Sachin Tendulkar found his spark in cricket, Lata Mangeshkar in singing—and we all know where their dedication took them. But even if you haven’t found your “kick” yet, don’t worry. Just keep moving forward. Stay curious, keep your eyes, ears, and mind open. Sooner or later, you’ll find what truly drives you—and when you do, everything starts to align.
When you’re living in a society with this growth mindset, it’s natural for your mind and those around you to start comparing your journey with others. Family, friends, peers, even your own thoughts may nudge you into this race of constant comparison. But here’s the truth: the only meaningful competition is with yourself. Focus on being better than who you were yesterday. Let me share a personal experience to put this into perspective.
During my BTech at VNIT, Nagpur, after switching my branch to Mechanical Engineering, I found myself suddenly surrounded by top-performing students. I still remember; in the second year itself, the branch topper scored a perfect 10.0 GPA in the third semester. That moment hit hard. It made me realize just how intense the competition was. But instead of being intimidated, I chose a different path: no comparisons, just progress. I told myself, “I’ve scored a 9.3 this semester. My next goal is 9.5, then 9.7, 9.9 and so on.” I kept aiming higher, not to outshine anyone else, but to outdo my own past self. There were moments of doubt, of course. Times when I felt like I was falling behind or out of the race. But I stayed consistent, trusted my process, and eventually, the results spoke for themselves. In semesters 5, 6, and 8, I scored a perfect 10.0 GPA, and I ended up as the department ranker of my batch. I was the only student in the entire college to score a perfect GPA in three out of eight semesters during engineering. I’ll let you draw your own conclusion from that!
While this is an example from academics, I truly believe the principle applies universally—whether it’s sports, culture, art, music, or any other field. The key is consistent self-improvement, self-calibration and not comparison with others.
Future Plans?
As I mentioned earlier, my core motto has always been: “Leveraging my technical skills and abilities in the service of mankind.” With that in mind, I’ve been consciously calibrating myself and moving forward in alignment with this purpose. Driven by passion and enthusiasm, I follow the principle of “one day at a time” or “one step at a time.” Right now, my focus is on gaining versatile industrial experience in my field and understanding its practical applications in real-life scenarios. I set short-term goals, work towards accomplishing them, recalibrate myself based on the learnings, and then move on to the next milestone. This process not only keeps me grounded but also ensures continuous growth. With open eyes, ears, and mind, I’m actively seeking better platforms and opportunities that can help me contribute more meaningfully and evolve further in my journey.