Sayantan Sengupta

Materials and Process Engineer (Composites) @McLaren Engineering

Guelph, ON, CA

Led development of Type IV conformable hydrogen storage vessels, ensuring compliance with CSA/ANSI CHMC 2, UN GTR No. 13, and Transport Canada regulations.Developed thermoset resin systems, achieving rapid cure and high thermal stability.Conducted thermal (DSC, TGA), rheological, and mechanical (DMA, tensile, compression) testing for material selection and validation.Designed braided carbon fiber overwraps and tow-preg processes to optimize burst strength and weight.Executed burst, permeation, and fatigue testing per ISO/CSA standards and supported failure analysis of liners and fiber systems.Sourced and validated protective coatings for abrasion and impact protection using ASTM D4541 and D2794 testing.Developed and tested fire-resistant coatings (intumescent and ceramic) for battery trays and hydrogen tanks; validated using UL 94 and FMVSS 302.Conducted durability studies on coatings (UV, salt spray, thermal cycling) for long-term automotive performance.Led structural SMC battery enclosure development, focusing on material selection, mechanical testing, and flame resistance.Supported design and mold teams with cure simulations, fiber orientation analysis, and warpage evaluations.Assessed composite alternatives to metal battery covers for crash, EMI, and thermal performance.Contributed to SR & ED claims by documenting material and process innovation.Worked cross-functionally with design, FEA, testing, and manufacturing teams.Mentored junior engineers and co-ops on composite testing, processing, and regulatory standards