Kiran Kumar
Kasuvosula

About

I started my career in continued airworthiness, assessing repair life, residual strength and inspection thresholds on commercial jets. Over twelve years I grew into a project leader delivering fairings, trailing edges, fuselage integration and wing slats from preliminary design to certification, including long onsite assignments in the USA and Japan.

I then founded an engineering design and CAE consultancy for railway chassis programs, and today I lead aerostructures new product development: prototype test plans, test-vs-analysis correlation and certification reporting.

Alongside the structures work I build software. My current focus is agentic AI for engineering: multi-agent pipelines that turn 3D CAD into bills of material and shop-floor instructions, with a human approval gate at every step. That work earned the Best Innovation Award 2026.

Where I work on the airframe

Tap a marker to see the structure, the checks behind it and a drawing of the area.

Area 1 of 5

Mid-body integration

←→

Selected work

Run live demo ~1 MB · runs in your browser

Live · personal project

DigitalWork Instructions

A from-scratch 3D assembly and work-instruction viewer. Parts install in sequence with an animated camera; explode, X-ray and a large-type shop-floor mode make it usable on a tablet at the workbench.

• 73 → 0.9 MBCAD to web model
• 57parts, 11 steps
• 0servers needed

• Three.js
• OpenCASCADE
• glTF-Transform
• Vite

Read the case study Open full screen ↗

Drawing review Stack-up 3D studio 3D tour

Training platform · engineering teams

GD&T Aerospace Academy

A role-based, zero-to-hero GD&T course for business development, design, manufacturing and stress teams, told as one story about a quarantined batch of wing hinge fittings. Every topic runs on the same drawing, with 3D tours, worked examples, hands-on sheets and a Tolerance Studio for real stack-ups.

• 5 levelsfrom drawing basics to master
• 4 teamsBD · design · build · stress
• WC · RSS · MCstack-up methods, plus STEP-based 3D

• ASME Y14.5
• React
• Three.js
• OpenCASCADE
• Node.js
• AI tutor

Experience

1. 2024 — Now

   Manager – Aerostructures NPD & AI Engineering Tata Advanced Systems

   Lead airframe programs from preliminary design through prototype test plans, test-vs-analysis correlation and certification reporting. Architect of an agentic CAD-to-manufacturing-instructions platform; run SDLC delivery and present to executive leadership to win approval for implementation.

   • NPD
   • Certification
   • LangGraph
   • RAG
   • React
   • Three.js
2. 2020 — 2024

   Founder & Principal Consultant Kesari Group of Industries

   Engineering design and CAE consultancy: static, fatigue and weight-optimisation studies for railway rolling-stock chassis programs, plus business development and client delivery.

   • FEA
   • Fatigue
   • Client delivery
3. 2008 — 2020

   Project Leader – Aerostructures Design & Analysis Cyient

   Twelve years from repair-assessment analyst to onsite project leader. Metallic, composite and sandwich structures from preliminary design to certification; test plans, flight-test installation and FAA-PMA packages; led a distributed India–Japan team.

   • 2016–2019 Onsite, Japan · ShinMaywa programs
   • 2011–2015 Onsite, USA · Boeing programs

   • Stress analysis
   • Fatigue & DT
   • HyperMesh
   • Nastran / Patran
   • Abaqus

Toolbox

Learn

A free hub launching soon: notes, worked examples and calculation sheets from 18 years on aircraft structures. Every analysis topic follows one rule: hand calculation first, then the FE model, then compare.