Rajasekar. K, Ph.D

• Conduct research on solvent-free dry mixing for lithium-ion battery electrodes with a focus on powder mixing and flow. • Design dry mix formulations to enable stress-free calendering, reducing particle fracture and improving structural integrity. • Apply particle surface engineering to enhance internal lubrication and enable high-density dry electrode manufacturing. • Correlate microstructure, mechanical properties, and electrochemical performance of dry electrodes to guide material design. • Characterize materials and electrodes, emphasizing powder properties via powder rheometry. • Established relationships between process variables, polymer addition, and measured carbon coating for dry electrodes.

• Part of the Green field project for the development of 4680 cylindrical high-density lithium cells, guiding a cross-functional team from inception to implementation, revolutionizing energy storage solutions. • Spearheaded the solvent-free electrode(Dry Battery Electrode) coating project as a Process Engineer, driving innovation and sustainability in battery manufacturing processes. • Engineered and optimized mixing and calendaring processes for Cathode and Anode materials, ensuring peak performance and quality standards. • Established precise operating parameters with the MRC 450 multi-roll calendaring machine, maximizing production capabilities. • Employed Design of Experiments (DOE) methodologies to optimize mixing processes, driving efficiency gains and product quality enhancements. • Utilized advanced online quality control equipment for real-time monitoring and validation of production processes, ensuring consistency and precision. • Applied expertise with the FT4 particle rheometer to analyze particle behavior, providing insights for process refinement and continuous improvement

• Conducted numerical analysis of wet coating process using OpenFOAM and COMSOL Multiphysics. • Developed slot die heads for innovative wet coating processes at Indian Institute of Information Technology Design & Manufacturing Kancheepuram. • Integral part of the Integrated Clean Energy Material Acceleration Platform (IC-MAP) funded by Department of Science and Technology, India.

Led CFD analysis of spray drying process for particle engineering, optimizing heat and mass transfer mechanisms, and developing carbon-agglomerated sodium-ion (Na-ion) active materials. • Conducted Ansys Fluent Discrete Phase Modelling approach for CFD analysis. • Focused on optimizing heat and mass transfer mechanisms of the spray drying process for controlling the particle morphology. • Developed carbon-agglomerated sodium-ion (Na-ion) active materials using the custom-made spray dryer.