Aum Suthar
630 615 0638 | aumksuthar@[Link] | [Link]/aumsuthar | [Link]/aumsuthar
Education
The Ohio State University Columbus, Ohio
B.S. in Materials Science and Engineering Aug. 2022 – Dec. 2026
Skills
Materials Characterization: SEM, EDS, XRD, XRF, FTIR, DSC, TGA, Optical Microscopy, Metallography,
Microhardness (Vickers/Knoop), Rockwell Hardness
Mechanical Testing: Tensile Testing, Compression Testing, Fracture Toughness, Creep Testing
Manufacturing Processes: FDM Additive Manufacturing, Casting/Pouring, Heat Treatment
CAD/Simulation: SOLIDWORKS, Creo, NX, Inventor, Fusion 360, COMSOL
Standards & Quality: ASTM, ISO, GD&T, DOE, Continuous Improvement
Data Analysis & Programming: MATLAB, Minitab, Python, Excel, LabVIEW, PowerBI, Tableau
Materials Software: MIPAR, MDI Jade, EDAX TEAM, Ansys GRANTA, ImageJ
Other Tools: Teamcenter, Microsoft Suite, ESP32, Soldering, Oscilloscope, Calipers, Strain Gauges
Experiences
SpaceX Sep. 2025 – Dec. 2025
Thermal Hardware Intern Cape Canaveral, Fl
• Designed adaptive end effectors accommodating 50+ Starship heatshield tile variants, enabling automated handling
across current and future tile geometries without tooling changeovers.
• Leading an estimated $500k capital expenditure project to automate Starship heatshield production material
handling, driving scalability improvements with an 6-month ROI.
• Implementing hardware reliability improvements to existing environmental test cells across Starbase and Cape
Canaveral facilities for Starship heatshield, targeting 90%+ OEE through systematic optimization.
Collins Aerospace May 2025 – Aug. 2025
Materials and Process Engineering Intern Rockford, IL
• Collaborated with 30+ internal and external customers to perform materials characterization, delivering
comprehensive technical reports for failure analysis, novel manufacturing investigations, and quality assurance.
• Completed new operator qualification on 20+ braze joints via metallographic examination per internal
specifications and issued formal reports detailing results.
• Analyzed structural adhesive shear strength for NASA Orion program using aluminum etching and tensile testing
to validate bond performance specifications.
Caterpillar May 2024 – May 2025
Manufacturing Engineering Intern Peoria , IL
• Secured $30,000 in funding through stakeholder presentations to enhance product development processes by
optimizing manufacturing and defect detection with IoT and machine learning.
• Achieved 85% defect classification accuracy by developing a machine learning program in Python Tensorflow
capable of detecting weld quality using weld acoustics in real time.
• Created a prototype wearable defect notifier system for welders using a SOLIDWORKS, ESP32, USB-C interface
system, 3D printing, and mini display to enable wireless customized defect delivery of weld quality.
• Saved $30,000 annually in production costs by modeling sputtering targets using 3D scanning metrology and
Geometric Dimensioning and Tolerancing (GD&T) techniques.
Argonne National Laboratory May 2023 – Aug. 2023
Robotics Intern Lemont, IL
• Pioneered fully automated remote high throughput experimentation, using Universal Robot UR3e robotic arm,
achieving uninterrupted operation from 0 to over 3 cycles without human intervention.
• Developed a scalable automation algorithm in Python, integrating with URCap and beamline/instrument controls
to support future design modifications and automatically determine sample positions.
• Saved over $4,500 annually and reduced experimental downtime by engineering a microcontroller-based modular
robotic pipetting solution, enhancing precision in liquid handling.
Argonne National Laboratory 2020 – 2022
Volunteer Student Researcher — Advanced Photon Source Greater Chicago Area, IL
• Developed the first self-guided AI robot for 3D thermal and spatial mapping in a Department of Energy (DOE)
facility in collaboration with facility staff.
• Enhanced safety and environmental monitoring during high-radiation operations using the FLIR Lepton infrared
camera and DHT22 sensors for data-driven detection of climate irregularities and thermal hotspots.
• Presented and published research at the 2020 International Conference on Synchrotron Radiation Equipment.
Publications
AI Augmented Robot for Surveillance of High Radiation Facilities Jul. 2021
11th Mechanical Engineering Design of Synchrotron Radiation Equipment and Instrumentation (MEDSI’20)
Developed an AI-driven robotic system for monitoring high-radiation environments, specifically designed for
use at particle-accelerating facilities.
Leadership and Involvement
Artificial Intelligence Robotics Club (AIRC) | Founder and President Aug. 2023 – Present
• Founded AIRC from inception to 130+ members, establishing organizational structure, recruiting strategies, and
event programming to create one of the university’s largest technology student organizations.
• Secured industry partnerships with companies including JPMC and Accenture, coordinating executive speaker
series and networking events that connected students with career opportunities and mentorship
• Led workshop development and delivery at MakeOHI/O (Ohio’s largest student-led makeathon), expanding the
organization’s reach as a leader in the undergraduate tech community at OSU.
• Led a team of 8-10 students in developing an 1/10th scale autonomous vehicle, guiding them in the use of machine
vision, robot operating system (ROS), and systems integration for the F1Tenth autonomous vehicle challenge.
Leading Expeditions | Fisher College of Business | Recruitment Coordinator, Ambassador Aug. 2024 – Present
• Achieved 80% applicant conversion rate through strategic recruitment initiatives, improving participant engagement
and commitment.
• Facilitated leadership development workshops during classroom sessions and on-expedition training, mentoring
participants through experiential learning exercises and real-time challenges in high-stakes outdoor settings.
• Led recruitment strategy by co-facilitating weekly progress meetings, organizing campus outreach events, and
implementing targeted engagement tactics.
Projects
Additive Manufacturing of Disaster Food Storage Solution Feb. 2023 – Mar. 2023
• Engineered a portable, stackable, food-grade storage solution addressing urgent deployment needs and scalability
for natural disasters and food emergencies through material research and rapid prototyping.
• Awarded $500 and runner-up in the Society of Manufacturing Engineers Digital Manufacturing Challenge.