Shreyas B Karadi
Dean's List @Duke University | Prestigious | Scholarship Recipient | Private Pilot | Active researcher
About Me
I'm a senior Mechanical Engineering student at Duke University specializing in aerospace systems, advanced manufacturing, and mechanical design. My work spans aeroelasticity research, propulsion systems, and FSAE chassis development—solving complex engineering challenges where design, materials, and performance intersect.
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Experience & Recognition: Through internships at Safran/Hindustan Aeronautics and Trio Labs, I've developed industry-relevant expertise in CAD design, CFD analysis, and manufacturing processes. My academic excellence has been recognized through the Dorcas Maynor and E. Ray Bucher, Jr. Scholar and Bee-Keng Boey Scholar awards, supporting advanced research in Aerospace and Materials Science at Duke's premier laboratories.
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Aviation & Leadership: As a licensed private pilot and active Duke Aviators Club member, I combine technical engineering rigor with hands-on aviation experience. This unique perspective—bridging theoretical aerospace principles with practical flight operations—drives my approach to designing systems that perform under real-world conditions.
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I bring proven leadership, cross-functional collaboration skills, and a passion for pushing the boundaries of aerospace innovation to every engineering challenge.
Key Highlights:
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Published research on aeroelasticity in a peer-reviewed journal
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Led a team project on sustainable materials for aerospace applications
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Completed a private pilot license, enhancing understanding of aviation dynamics
Professional Experience
Mechanical Engineering Intern
Trio Labs | Durham, North Carolina, USA
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Increased productive capacity by 25% through process optimization and workflow improvements
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Created innovative chemical transfer process, dramatically increasing efficiency by 90%
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Devised and conducted comprehensive testing protocols for new 3D printers, troubleshooting issues before commissioning and increasing production by 50%
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Implemented Kaizen and Lean Manufacturing principles to streamline operations
Mechanical Design Engineering Intern
Safran & Hindustan Aeronautics Ltd | Bengaluru, India
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Analyzed various compressor blade designs and materials for aircraft engines, evaluating impact on performance and durability
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Conducted extensive research on potential new alloys and metals for compressor blades and combustion chambers to enhance heat resistance and reduce manufacturing costs
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Gained comprehensive hands-on exposure to turbine engine manufacturing processes and material selection challenges in high-temperature environments
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Collaborated with international engineering teams on advanced aerospace propulsion systems
Chassis Design and Assembly Engineer
Duke University Motorsports
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Designed and manufactured precision support jigs for chassis tube welding, improving assembly accuracy and structural integrity
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Created detailed engineering drawings of pedal box tubes in SolidWorks, ensuring FSAE regulation compliance
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Utilized advanced CNC machining techniques to enhance brake pedal box build quality and component precision
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Led cross-functional team collaboration for integrated vehicle systems design
Aeroelasticity Lab Research Assistant
Duke University
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Conducted cutting-edge experimental and computational analysis of flexible riblet designs for drag reduction in turbulent flow
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Fabricated precision riblet samples using 3D printing, laser cutting, and soft materials; performed wind tunnel tests with load cell instrumentation
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Utilized advanced CFD tools (ANSYS Fluent, FUN3D) for steady flow modeling with various turbulence models
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Established repeatability protocols and uncertainty quantification for experimental validation
Materials Science Lab Research Assistant
Volker Blum Lab | Duke University
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Conducted advanced research on chalcogenides and oxide perovskites for next-generation solar cell materials
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Maintained and enhanced the globally accessible Muchas database, improving research efficiency worldwide
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Utilized DataGrip, MySQL, and GitHub for large dataset management and organization
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Identified potential materials with optimal band gaps and industrial scalability for silicon replacement
Featured Projects
Design and Fabrication of Riblet Surfaces for NACA 0015 Airfoil
CFD Analysis| 3D Printing| Wind Tunnel Testing | SolidWorks | ANSYS
I conducted an independent research project investigating how micro-structured riblet surfaces influence boundary layer behavior on a symmetric NACA 0015 airfoil. Two riblet geometries were developed:
1) Sawtooth riblets with sharp triangular peaks designed to trip the boundary layer and alter transition/separation behavior.
2) Scalloped riblets with smooth sinusoidal grooves intended to reduce skin-friction drag and promote more stable near-wall flow.
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The riblets were parametrically modeled in CAD and 3D-printed at high resolution, allowing consistent surface quality across test samples. This approach enabled direct comparison of different riblet topologies under equivalent conditions.
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The project strengthened my expertise in aerodynamic flow-control concepts, surface topology design, additive manufacturing, and preparing physical prototypes for aerodynamic evaluation.
It also provided hands-on experience with biomimetic and engineered drag-reduction strategies, which can be applied in aerospace, wind energy, and marine contexts.
Linear Induction Motor (LIM) Assembly Design
SolidWorks| GD&T| Thermal Analysis| FEA| Mechanical Design
Engineered a custom Linear Induction Motor assembly for my college Hyperloop team, including motor coil housing and mechanical mounting structure designed to withstand electromagnetic forces while maintaining precise track alignment.
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Technical Execution:
1) Modeled complete assembly in SolidWorks with manufacturing-ready tolerancing and fastener specifications
2) Integrated thermal management systems for heat dissipation during motor operation
3) Designed vibration damping features to ensure stable high-speed performance
4) Created modular architecture enabling rapid assembly/disassembly for iterative testing
Collaboration:
Coordinated with electrical and propulsion sub-teams to ensure mechanical-electrical integration and compatibility with pod chassis architecture.
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Outcome:
Delivered a robust, testable propulsion system demonstrating expertise in electromechanical design, thermal analysis, and cross-functional engineering integration under competitive project constraints.
Next-Generation Solar Cell Materials Research
Material Science| Database Management | Python | MySQL | Research
Advanced materials science research focusing on chalcogenides and oxide perovskites as potential silicon alternatives in photovoltaic applications.
1) Contributed to globally accessible research database.
2) Identified potential materials with optimal band gaps for solar applications and industrial scalability
3) Enhanced globally accessible Muchas database for worldwide research community collaboration
4) Evaluated manufacturing feasibility and cost-effectiveness of alternative materials
5) Applied computational materials science principles for predictive analysis
6) Contributed to sustainable energy technology development and renewable energy advancement