Divya Dharshini S

Materials & Process Engineer with experience in materials R&D, polymer–metal composite, extrusion-based additive manufacturing, and powder metallurgy. Skilled in material characterization, compounding, debinding and sintering, process optimization, experimental design, and technical data analysis. Experienced in working across R&D, vendor coordination, raw-material qualification.

Strong problem-solving approach with hands-on experience translating experimental results into practical process improvements and scalable manufacturing solutions.

Materials and Process Engineer at THINKMETAL PVT LTD (2023-12 – Present)

Lead materials and process development for metal additive manufacturing, covering feedstock formulation, raw-material qualification, polymer processing, filament development, printing, debinding, sintering, and final part evaluation.

• Developed and optimized metal–polymer feedstock formulations for metallic systems including polymer/binder selection, composition optimization, material compatibility, and processability assessment.
• Performed raw-material characterization and qualification, including polymer testing such as MFI/MFR, DSC, TGA, density, moisture and FTIR, and metal-powder evaluation through particle-size distribution, morphology, chemical composition, flowability, apparent/tap density, and SEM/EDS.
• Executed twin-screw and single-screw extrusion, blending, and high-shear mixing for feedstock development, optimizing processing conditions to achieve consistent flow, filament quality, and processability.
• Developed and optimized Metal FFF/MFAM processes, including print-parameter selection, green-part evaluation, process troubleshooting, and print-quality improvement.
• Designed and executed debinding and high-temperature sintering cycles, including heating/ramp/soak profiles in controlled-atmosphere processing.
• Characterized filaments, green parts, and sintered components through dimensional, density, hardness, microstructural, and performance testing.
• Analyzed experimental data and material–process relationships to drive process optimization, root-cause investigation, and R&D improvements.

Intern at RANE BRAKE LINE LIMITED (2022-07 – 2022-08)

• Identified the sequence of operations involved in the production of Disc Pads and Brake Linings
• Learnt the methods of testing the physical properties and the raw materials that is used for preparing the composite. Performed quality analysis by comparing the results of testing with customer specifications

B.E in MATERIALS SCIENCE AND ENGINEERING – College of Engineering Guindy, Anna University (2019-07 – 2023-06)

HSC (HIGHER SECONDARY XII) – Pachamuthu Matric Hr. Sec. School (2018-01 – 2019-01)

SSLC – Pachamuthu Matric Hr. Sec. School (2016-01 – 2017-01)