At OnestopNDT, we love bringing real stories and expert voices from the Non-Destructive Evaluation (NDE) world to our community. Today, we’re excited to sit down with Mr. Manoharan, a seasoned NDE professional with over 35 years of experience in industries like nuclear, aerospace, and manufacturing. Currently the CEO of CNDE at IIT-Madras, his journey has taken him through leading institutions like BARC, IGCAR, GE Global Research, and Visiconsult, where he’s played a key role in advancing digital radiography, AI-driven inspections, and imaging technologies.
In this conversation, he shares his career journey, thoughts on NDE’s future, and the challenges shaping the industry today. We hope you’ll enjoy reading his inspiring journey.
Mr. Manoharan, it’s an absolute pleasure to have you with us today! To start things off, could you share a bit about yourself and walk us through some highlights of your remarkable professional journey? What inspired you to dive into the fascinating world of NDE?
Thank you for inviting me to participate in the OnestopNDT interview series. I am thrilled to talk to you today.
I grew up in the village of Pilrampattu in Tamil Nadu, where I attended local government schools. I earned a degree in Physics from Madras University and received training in Radiological Physics at the Bhabha Atomic Research Center in Mumbai.
I had the opportunity to work as a medical physicist in hospitals and as a Radiological Safety Officer in the non-destructive evaluation (NDE) industry. I initially chose to explore the NDT field and joined an NDT service organization in 1986. Later, in 1988, I returned to the Bhabha Atomic Research Center, where I worked in Quality Control for Mixed Oxide (MOX) Nuclear Fuels.
I was fortunate to be trained by Dr. Jose Pannakal in various techniques, including Radiography, Leak Testing, Gamma Autoradiography, X-ray Diffraction (XRD), X-ray Fluorescence (XRF), and Metallography. My passion for Non-Destructive Evaluation (NDE) began during this training. After eight years at BARC, I joined the Indira Gandhi Center for Atomic Research in Kalpakkam in 1996, where I focused on NDE of nuclear reactor components. I worked closely with Dr. B. Venkatraman, who further enhanced my NDE expertise by introducing me to advanced technologies such as Microfocal Radiography, Digital Radiography, and Infrared Thermography.
In 2001, I joined GE Global Research Center in Bangalore. GE has significantly shaped my professional career in non-destructive testing (NDT). I gained expertise in various NDE technologies, industries, applications, project management, leadership, innovation and people management skills during my time there. Collaborating with distinguished colleagues such as Dr Shyamsunder, Dr Debasish Mishra, Dr Cliff Bueno, Joe Portaz, Dr Greg Mohr, Dr Tom Batzinger, Dr Forrest Hopkins, Raj, Megha, Prasad, Nityanand, Prafull Sharma, and many others at GE greatly enriched my knowledge in NDE.
I retired from GE in 2020 and joined Visiconsult in 2021, a prominent German manufacturer of X-ray imaging systems. I supported them in establishing a facility in India, which gave me a different perspective on NDT equipment manufacturing. I worked closely with Hajo, the founder of Visiconsult, Rajesh Kulkarni (General Manager), Anand, and Chakravarthy.
In 2024, I joined the Center for Nondestructive Evaluation (CNDE), IIT-M, as its first-time CEO, working with Prof. Krishnan Balasubramanian and Prof. Prabhu Rajagopal.
It has been a long journey in NDE for over 35 years.
Congratulations on receiving the prestigious ISNT Honorary Fellow Award! That’s such an incredible honour. Looking back, how did it feel to be recognized at that level?
I am deeply honored to have been awarded the ISNT Honorary Fellow Award in 2023 in recognition of my contributions to the field of Non-Destructive Evaluation (NDE) and to the NDE community. My association with the Indian Society for Non-Destructive Testing (ISNT) spans over 30 years, during which I have engaged in various roles serving the NDE community, including the conduct of NDT training programs, workshops, and pre-conference tutorials. Furthermore, I have had the privilege of serving as a member of the technical committee for NDE conferences.
I currently serve as the Chief Controller of Examinations for the National Certification Board and hold the position of Chairman of the Program Formulation and Management Board. Throughout my career, I have made significant contributions to the NDE community, which has equipped me with extensive experience in organizing events and collaborating effectively within team environments.
Did it open new doors or inspire you to take on fresh challenges?
My passion for non-destructive evaluation (NDE) has been rekindled, driving my desire to make significant contributions to the field. This renewed enthusiasm motivates me to actively engage with the NDE community, sharing knowledge and fostering a collaborative environment where we can all succeed together.
You’ve worked in high-stakes industries like nuclear and aerospace, where the margin for error is razor-thin. What’s the most complex NDE methodology you’ve ever developed, and how did you and your team manage to overcome the toughest hurdles?
I was part of the team that implemented micro focal radiography for inspecting tube-to-tube sheet welds in the heat exchangers of fast breeder reactors. Implementing micro focal radiography in a factory was challenging in 1997 because the technology was not fully developed. This achievement was made possible through collaboration with a multidisciplinary team.
We began transitioning Digital Radiography Technology (Digital Detector Arrays) to GE Aviation in 2001. At that time, our understanding of DDAs' image quality was in its nascent stage. We collaborated with Bangalore, Niskayuna, and Cincinnati teams to understand image quality and develop tools for measuring and optimizing it.
In 2006, we started working on developing Industrial Volumetric Computed Tomography for aviation applications. One major challenge we faced was scattering artefacts. Working as a team, we created a hardware-based scatter correction tool, which we patented. This innovation is a differentiator for the industrial tomography systems commercially available today.
Can you tell us about a recent breakthrough or research project in NDE that you’re especially proud of. What excites you the most about its potential to reshape the industry?
Our team at CNDE is focused on the development of metamaterials-based ultrasonic imaging. This team has recently achieved a remarkable resolution of 50 microns for bulk ultrasonics for the first time, utilizing innovative micro-fabricated metamaterial lenses. This advancement presents a viable pathway for conducting material diagnostics at greater depths with high resolution in the future, employing micro-metalens-enhanced ultrasound as a cost-effective and less radiation-intensive alternative to traditional electromagnetic techniques.
Digital X-ray imaging has come a long way. From your perspective, how have 2D and 3D technologies evolved over time? What are some of the most groundbreaking applications you’ve seen in action today?
I began my journey in digital X-ray imaging in 2001, focusing on understanding image quality from the perspective of industrial inspection. This field has matured significantly and is now supported by various international standards. The integration of AI technologies further enhances its capabilities. Digital X-ray imaging is widely accepted in the automotive industry for inspecting castings, as it helps meet productivity requirements.
In 2006, I became involved in the development of volumetric computed tomography (VCT) systems, which we used for inspecting gas turbine blades. VCT's exciting applications include additive manufacturing and lithium-ion batteries.
As the CEO and mentor at CNDE, you’ve played a pivotal role in shaping the future of NDT professionals. What has been the most rewarding aspect of leading such a respected organization, and how do you approach fostering growth and innovation within the CNDE community?
I am honoured to be a part of CNDE, one of the leading organizations in the field of non-destructive evaluation (NDE) research worldwide. As I embark on this journey with CNDE, I recognize it as a significant responsibility rather than just a role. Being part of such a well-established organization presents a considerable challenge, and I am dedicated to contributing to its growth and improvement. My responsibilities will include expanding research areas, enhancing external connections, supporting talent recruitment, and establishing processes to ensure the sustainability of the organization.
We are establishing a national consortium for non-destructive evaluation (NDE) to enhance collaborative research among industries. The CNDE aims to address real-world challenges faced by stakeholders in non-destructive evaluation (NDE) and structural health monitoring (SHM).
When it comes to setting up an NDE facility for industries like aerospace or nuclear, what are the critical things to get right from the start? Are there any unique challenges you’ve encountered that might surprise our audience?
One of the foremost challenges encountered in the establishment of a non-destructive testing (NDE) facility lies in the process of ensuring compliance with safety regulations and standards mandated by national regulatory bodies. This compliance not only encompasses the implementation of appropriate safety protocols but also requires a thorough understanding of relevant industry standards, potential hazards, and risk management strategies. To effectively navigate these complexities, it is imperative to incorporate compliance planning during the initial design phases of the facility.
You’ve worked across such diverse industries—O&G, nuclear, and aerospace. How have these experiences shaped your approach to NDE? What unique insights have you gained from working in these vastly different fields?
Each industry faces unique challenges, and the delivery mechanisms for non-destructive testing (NDE) technology can vary accordingly. The oil and gas (O&G) industry requires either portable or permanently installed sensors that meet relevant safety standards. The nuclear industry must adhere to the highest standards of quality and reliability while also considering the effects of radiation damage on systems. In aerospace, there are stringent standards for quality that must comply with the regulatory requirements of the aviation sector.
The field of NDE is constantly evolving. What are some of the emerging trends in NDE technology that excite you the most? How do you see these advancements transforming the industry in the next decade?
NDE 4.0 represents the latest trend in non-destructive evaluation (NDE). Traditional non-destructive testing (NDT) is evolving through the integration of robotics, drones, the Internet of Things (IoT), artificial intelligence (AI), machine learning, digital twins, augmented reality (AR), and virtual reality (VR). These advancements are significantly enhancing NDE capabilities and delivery mechanisms.
The Center for Non-Destructive Evaluation (CNDE) emphasizes several advanced technologies, including continuously distributed sensing using fibre optics and guided wave ultrasonic sensors for high-resolution monitoring over large areas. Additionally, the exploration of metamaterials for ultrasonic imaging aims to achieve even greater resolution. Other key focus areas include edge intelligence, soft sensing, quantum photonics, and nanostructured coatings, which extend beyond the scope of NDE 4.0.
I am personally excited to see the progress of muon tomography for inspecting large structures.
Sustainability is on everyone’s radar these days. How can NDE methodologies contribute to creating greener, more sustainable practices, especially in industries like energy and O&G?
Non-destructive testing (NDT) is essential for ensuring the structural integrity of various systems employed across multiple industries, including manufacturing, aerospace, and energy. This proactive methodology not only facilitates the early identification of potential flaws or weaknesses but also plays a significant role in minimizing the environmental impact associated with industrial operations. By reducing emissions and preventing catastrophic failures that could result in environmental disasters.
For young professionals who aspire to make a mark in NDE—particularly in research and technology development—what advice would you give them? How can they set themselves apart in this competitive and technical field?
Achieving success in Non-Destructive Evaluation (NDE) requires a commitment to developing specialized technical expertise as well as a broader understanding of the discipline. It is essential to gain in-depth knowledge in your specific area of interest while also exploring various aspects of NDE.
Establish connections with relevant industries and academic institutions that align with your expertise. Essential skills include proficiency in software, artificial intelligence (AI), machine learning (ML), and image and signal processing. Additionally, strong computational skills and familiarity with modelling and simulation tools are vital.
Having a comprehensive understanding of the challenges faced by various industrial sectors—such as aerospace, automotive, oil and gas, and energy—can provide you with a significant competitive advantage.
Join a professional society and actively participate in its activities, as this engagement will foster your growth in the field. Furthermore, obtaining NDT certifications is beneficial as it helps you understand field inspection requirements and supports your efforts to develop technology for commercial applications.
Outside of work, we’d love to know—do you have any hobbies or interests that might surprise us and the audience? What’s your go-to way of unwinding after a busy day?
There's nothing to surprise. I spend time with my family, play with my grandkid and pet dog, and listen to music. I love all forms of music: Indian classical, movie songs, folk songs, and devotional songs.
Are there any books, movies, or shows that have inspired you or offered a fresh perspective on innovation or problem-solving? We’re always curious to hear about unexpected sources of inspiration!
Honestly, no. I am not underestimating it. However, my sources of inspiration for innovation are the challenges before you, a passion for solving problems, quickly testing your ideas, and the team members working with you.
Mr Venugopal, can you share a few challenges the NDT Industry is currently facing?
In addition to technical challenges related to new materials, manufacturing processes, complex systems, faster inspections, economic factors, wider area inspections, and continuous monitoring, one significant challenge faced by industries is the shortage of trained and skilled personnel in the field of Non-Destructive Testing (NDT) which need to be addressed.
Finally, what are your thoughts on OnestopNDT? Do you think our efforts to provide real, authentic and accurate content are helping the NDT industry? Also, do you think our platform helps the community connect with like-minded people
Onestop NDT has made a meaningful contribution by centralizing all relevant information about non-destructive testing (NDT) in one place. The details regarding NDT companies, products, career opportunities, training courses, and expert interviews will undoubtedly benefit both individuals and industries. I wish them to be successful in connecting people working in NDE.
