Led innovative research to address the limitations of traditional metal 3D printing (e.g., SLM/SLS) by developing a low-cost fused deposition modeling (FDM) process for fabricating polymer-metal composite parts with high metallic content (>50% vol.) under the supervision of Professor Amir Hosein Behravesh.
During my master’s program, I specialized in additive manufacturing (AM) and advanced material processing, combining rigorous coursework with groundbreaking research to develop low-cost, high-performance solutions for metal 3D printing. Supervised by Dr. Amir Hoesin Behravesh, my work focused on bridging the gap between traditional manufacturing and cutting-edge AM technologies, with a thesis centered on Fused Deposition Modeling (FDM) of polymer-metal composites. Below is a detailed overview:
Thesis: Innovative FDM-Based Fabrication of High-Metal-Content Polymer-Iron Composites
Objective: Develop a cost-effective FDM 3D printing process to produce near-net-shape metal parts with >50% metal volume, circumventing the high costs of laser-based systems (SLM/SLS).
Materials Science: Composite formulation, additive selection, sintering behavior, and phase compatibility analysis.
Process Development: Troubleshooting extrusion parameters, feedstock rheology, and printer configurations.
Analytical Testing: SEM, TGA, and microstructure analysis for quality assurance.
Software & Programing: SOLIDWORKS, CATIA, MATLAB, Python, R, EES, ANSYS, Geomagic, Creatware, Simplify3D,and Numerical modeling tools for process simulation and optimization.
My work directly addresses industry demands for affordable, scalable metal AM, particularly for
prototyping and low-volume production. By leveraging FDM’s simplicity, this research opens avenues for
SMEs to adopt metal 3D printing without heavy capital investment. Further description of my thesis is
under the topic “Master’s Thesis Description”.
This advanced education and research experience have equipped me to lead projects at the intersection
of material innovation, process engineering, and additive manufacturing, with a focus on practical,
industry-driven solutions.
During my internship at Iran Air, one of Iran’s largest and most advanced aviation companies, I gained hands-on experience in aircraft maintenance, structural repair, and workshop operations. My role focused on applying mechanical engineering principles to ensure aircraft safety, performance, and compliance with stringent aviation standards. Below is a summary of my key responsibilities and achievements:
Technical Proficiency: CNC machining, composite repair, hydraulic/pneumatic systems, and metallurgy.
Analytical Tools: Non-destructive testing (NDT), thermogravimetric analysis (TGA), and stressstrain evaluations.
Industry Standards: SRM, CMM, AMM, and FAA/EASA compliance.
This internship solidified my expertise in aircraft systems, material science, and precision manufacturing, while emphasizing the critical role of safety and innovation in aviation engineering. My hands-on exposure to advanced workshops and real-world maintenance challenges has prepared me to contribute effectively to aerospace engineering and industrial projects.
Conducted in-depth research on aramid fibers (e.g., Kevlar®, Nomex®) and their role in advanced composite materials, focusing on mechanical properties, manufacturing processes, and industrial applications. Supervised by Dr. Karim Sheleshnazad, this project combined theoretical analysis with material science innovation to address challenges in lightweight, high-strength composite design.
Material Characterization: Stress-strain testing, fracture mechanics, and fatigue analysis.
Process Design: Extrusion, weaving, and prepreg fabrication for composite manufacturing.
Software & Tools: CAD for structural simulation, MATLAB for numerical modeling.
Industry Standards: ASTM testing protocols for tensile strength, compressive load, and thermal degradation.
Aerospace: Lightweight fuselage panels, radomes, and engine components.
Defense: Ballistic armor, helmets, and blast-resistant materials.
Civil Engineering: Reinforcement for bridges and seismic retrofitting.
Automotive: High-performance brake linings and clutch systems.
This thesis underscores my expertise in composite materials, mechanical design, and industrial problem-solving, positioning me to contribute to innovation in materials engineering and advanced manufacturing
Throughout my bachelor’s degree in Mechanical Engineering with a focus on Manufacturing and Production, I developed a robust foundation in core engineering principles and specialized expertise in modern manufacturing processes. My coursework and hands-on training emphasized the integration of theoretical knowledge with practical application, preparing me to address complex engineering challenges. Below is an overview of my key competencies and academic focus areas:
Design & Analysis: Proficient in technical drawing, machine elements design (I & II), jig and fixture design, and computer-aided design (CAD/CAM). Applied principles of statics, dynamics, strength of materials, and thermodynamics to solve engineering problems.
Material Science: Studied metallurgy, material behavior, and processes such as casting, welding, pressing, and plastic deformation. Gained expertise in material selection, machinability, and heat transfer applications.
Systems & Controls: Explored applications of hydraulics, pneumatics, electronics, and numerical control (NC) machines. Analyzed vibrations and measurement systems for precision engineering
Advanced Manufacturing Techniques: Hands-on experience with universal machine tools, numerical control (NC) programming, and specialized production methods. Designed pressing molds and fixtures for manufacturing efficiency.
Process Optimization: Investigated manufacturing workflows, including plastic technology, casting, welding, and metal-forming processes. Utilized computational tools for numerical analysis and statistical quality control.
Automation & Robotics: Trained in computer-aided manufacturing (CAM), automation systems, and the integration of electronics in mechanical systems.
Workshops & Labs: Completed extensive lab work in machine tools, casting, welding, measurement systems, and hydraulics/pneumatics. Developed prototypes and optimized manufacturing setups.
Capstone Project: Executed a specialized project focused on innovative manufacturing solutions, demonstrating end-to-end design, analysis, and implementation skills of “Aramid Composites”. The detailed description of my Bachelor’s project can be found under the label “Bachelor’s Project”.
Internship: Gained industry experience through a structured internship, applying classroom knowledge to real-world production environments. This important experience was gained in Iran Air. During my Internship in Iran Air I went through and practiced all types of checks, maintenance, and part manufacturing in hangars and in workshops. The thorough description is under the topic “Internship: Iran Air”
Software & Programming: Proficient in engineering software for design and simulation, including: SOLIDWORKS, CATIA, G-coding, ANSYS, Festo, EES, etc.
Developed problem-solving skills through courses in computer programming and numerical methods.
Multidisciplinary Skills: Integrated concepts from fluid mechanics, heat transfer, and electronics to address interdisciplinary engineering challenges.
This comprehensive education has equipped me with the technical acumen and problem-solving skills necessary to contribute effectively to manufacturing innovation, process optimization, and mechanical system design.