Gururaja Sethurao PhD(BITS-Pilani), Postdoc (IIT-B), MISTE
A highly motivated researcher specializing in AI/ML-driven predictive modeling and machine adaptation for manufacturing systems. I hold a Ph.D. from BITS Pilani, Hyderabad, where I developed intelligent solutions for real-time failure prediction and adaptive process control using machine learning and sensor integration. My work includes three patents (one granted, one published, and one filed) and multiple research excellence awards. I have developed AI-based real-time monitoring systems and reinforcement learning models for failure detection and process optimization, making significant contributions to the fields of smart manufacturing and predictive maintenance.
Currently, I am pursuing independent research as an ANRF-National Postdoctoral Fellow at IIT-Bombay in the domain of direct energy deposition of metals. My work primarily focuses on the development of advanced materials for high-performance engineering applications. I focus on combining data-driven materials design with additive manufacturing approaches to explore next-generation metallic systems. The research aims to strengthen the link between fundamental materials science and practical, application-oriented outcomes, with relevance to safety-critical and structural domains.
​My research work or on-demand work includes different components/aspects mentioned below:

CAD Modeling

Experimentation

Machine Learning

Numerical Simulation

Research Interests
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Micromachining
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Dynamic Stability Modelling
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Cutting Tool Dynamics
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Applications of AI/ML in Micromachining
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IoT enabled Manufacturing
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Digital Manufacturing
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Structural Condition Monitoring
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Digital Signal Processing
Education
Ph.D. in AI/ML for Manufacturing
Mentor: Prof. Kundan K Singh
BITS Pilani, Hyderabad Campus (2020 - 2025)
Achievement:
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Outstanding PhD Thesis Award
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​Excellence in Research Award
M.Tech in Machine Design
Mentor: Prof. C S Venkatesh (late)
UBDT College of Engineering (2014 - 2016)
Achievement: Best Research Paper Award
B.E. in Mechanical Engineering
PES College of Engineering (2010 - 2014)
Achievement: IV Rank
Research Services
Reviewer for the following journals
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Wear
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Engineering Applications of Artificial Intelligence
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Engineering
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Applied Intelligence
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Journal of Manufacturing Processes
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Journal of Advances in Sciences and Engineering
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Advances in Electrical and Telecommunication Engineering
Experience
Dec 2025 - Till Date
ANRF- National Postdoctoral Fellow
IIT-Bombay
June 2025 - Dec 2025
Visiting Faculty
Smart Manufacturing Division
BITS-WILP
BITS Pilani, Hyderabad Campus
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Nov 2020 - May 2025
Research Scholar
BITS Pilani, Hyderabad Campus
July 2016 - Oct 2020
Assistant Professor
Vidyavardhaka College of Engineering
June 2015 - July 2016
Project Assistant (Research Intern)
Indian Institute of Technology Madras
Membership in Professional Bodies
Life Member: Indian Society for Technical Education
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