Kundaneswar Pagadala
👋 AboutThis portfolio presents selected mechanical engineering projects spanning CAD design, simulation, mechatronics, and lightweight structures. The work emphasizes design-to-analysis workflows, manufacturability, and performance validation across aerospace, thermal, and electromechanical systems.🧩 Featured Work✈️SAE Aero Design East (Advanced Class) — RC aircraft design integrating aerodynamic optimization, CFD validation, and CNC-ready fabrication drawings.❄️Thermal Performance Validation of Optimized Heat Sink Designs — CFD comparison of advanced heat-sink geometries using ANSYS Fluent for high-performance computing applications.
🌀 CFD studies in multiphase flow, internal/external aerodynamics, and thermal systems.
🚗 Android-Controlled Bluetooth Car — Mechatronic prototype with Arduino control, 3D-printed suspension, and belt-driven torque enhancement.These projects demonstrate end-to-end development from concept through modeling, analysis, and validation.
Contact Information
SAE International Aero-Design East: Advanced Class (Technical Lead)Objective
Design and develop a fixed-wing UAV system for wildfire response, capable of delivering water and deploying a Powered Autonomous Delivery Aircraft (PADA) to transport components for a Ground Transport Vehicle (GTV).The system was engineered under SAE Aero Design competition constraints, including a ≤55 lb maximum takeoff weight and 9.84 ft wingspan UAV capable of carrying ~11 lb payload with an estimated endurance of 4.7 hours and range of ~95 miles.Click Here to know more.
Thermal Performance Validation and Comparative Analysis of Optimized Heat Sink Design
Design and evaluate optimized heat sink geometries for high-performance processors using CFD simulations to improve thermal dissipation and maintain safe operating temperatures.The study compared three aluminum heat sink designs (rectangular, rhombus inline, and rhombus staggered) for an Intel i9 processor heat source operating at 100 °C, analyzing airflow and liquid cooling performance using ANSYS Fluent simulations.
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Android-Controlled Bluetooth Car (Team Lead)Design and prototype a smart Bluetooth-controlled vehicle integrating mechanical systems, embedded electronics, and a Android/IOS application for wireless control.The system utilized an Arduino Uno R3 microcontroller, HC-05 Bluetooth module, and L293D motor driver to enable real-time control of vehicle motion and steering through an Android mobile application, demonstrating the integration of embedded systems, mechanical design, and wireless communication.Click Here to know more.
CFD Projects(Click on images to know more)
Internal Flow and Thermodynamics
Multi-Phase Flow
External Flow and Body Forces
Improving Aircraft Performance through CFD and Continuous Learning
While designing PA and PADA, I used CFD at multiple stages to guide key design decisions. I started by analyzing the airfoils to ensure they were suitable for gliding and STOL performance. After that, I researched various wing shapes and chose a semi-elliptical wing for its near-elliptical lift distribution and reduced drag. Finally, I performed CFD on the full integrated model—combining the PA's nose fuselage, wing, and tail assemblies with PADA mounted underneath—to evaluate overall aerodynamic performance.
"One of the most crucial aspects of design is the ability to effectively communicate concepts for fabrication and manufacturing, turning concepts into reality!"
Throughout this project, I created detailed drawings for the fabrication team and generated .dxf files for CNC laser cutting, both for prototypes and the final product.
Led the aerodynamic and aircraft design calculations for the Primary Aircraft (PA) and Powered Autonomous Delivery Aircraft (PADA) including wing sizing, tail sizing, weight estimation, and performance analysis.Selected and optimized airfoil configuration (S1223–N3412 interpolation) and semi-elliptical wing planform to improve aerodynamic efficiency for UAV Reynolds numbers (150k–400k).Designed the U-tail configuration based on comparative evaluation of efficiency, structural integrity, stability, and manufacturability.Performed aircraft sizing and performance calculations including thrust-to-weight ratio, wing loading (4.51 lb/ft²), service ceiling (~14,000 ft), and propulsion system selection.Contributed to system architecture and component selection including propulsion system (T-Motor P80-170KV motors, 28×9.2 propellers, 6S LiPo battery).Participated in fabrication and assembly of the UAV prototypes, supporting structural integration and iterative prototype improvements.Contributed to the automation and avionics integration for the PADA system, supporting autonomous payload deployment and precision landing mechanisms.
Customized 3D Printed Parts for Aircrafts Functionality
Universal BLDC Motor Mount
Horizontal and Vertical Tail Connector