Mechanical Engineering

Master’s Thesis: Development of Polymer-Metal Composite Feedstock and a novel process for Cost-Effective FDM 3D Printing of High-Density Metallic Parts

Tarbiat Modares University | 2017–2020

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.

:Key contributions

Research Scope & Methodology

  • Designed and optimized polymer-metal composite feedstock using iron powder (20–100 µm) and polyethylene/polylactic acid (PLA) matrices, incorporating additives like paraffin, stearic acid, and maleic anhydride to enhance material compatibility.
  • Engineered and tested multiple fabrication methods, including magnetic stirring, extrusion, fusion mixing, and dry mixing, to achieve uniform dispersion of metal particles in the polymer matrix.
  • Pioneered a direct extrusion FDM system to successfully print green parts with 91.7 wt.% iron (57.8% vol.) while mitigating phase separation and additive degradation.

Technical Achievements

  • Identified polyethylene (over PLA) as the optimal polymer matrix due to its thermal stability and compatibility with iron powder, enabling high metal content without binder burnout.
  • Validated material uniformity and sintering viability using thermogravimetric analysis (TGA) and scanning electron microscopy (SEM), confirming homogeneous metal-polymer distribution critical for post-processing.
  • Demonstrated the feasibility of FDM for producing complex, near-net-shape metal parts at a fraction of the cost of laser-based systems, advancing accessibility to metal additive manufacturing.

Skills Demonstrated

  • Material Science: Composite formulation, additive selection, and phase compatibility analysis.
  • Process Optimization: Troubleshooting extrusion parameters, feedstock rheology, and printer configurations.
  • Analytical Testing: TGA, SEM, and microstructure analysis for quality validation.

Master of Science in Mechanical Engineering (Manufacturing and Production)

Tarbiat Modares University, Iran | Graduated: February 2020

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:

Advanced Coursework & Technical Expertise

  • Additive Manufacturing Systems: Studied industrial production systems, additive manufacturing methods (e.g., FDM, SLM, SLS), and composite material design.
  • Computational Engineering: Applied advanced numerical methods and engineering mathematics to model material behavior and optimize manufacturing processes.
  • Polymer & Composite Science: Explored the physical/mechanical properties of plastics, composite fabrication, and material compatibility for hybrid systems.

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).

Key Contributions

Material Design & Optimization

  • Formulated polymer-metal feedstock using iron powder (20–100 µm) and polyethylene/polylactic acid (PLA) matrices.
  • Engineered additives (paraffin, stearic acid, maleic anhydride) to enhance bonding and prevent phase separation.
  • Identified polyethylene as the optimal matrix due to thermal stability and compatibility with iron powder.

Process Innovation

  • Pioneered a direct extrusion FDM system to print green parts with 91.7 wt.% iron (57.8% vol.)—surpassing traditional FDM limits.
  • Tested extrusion, magnetic stirring, and dry mixing methods, resolving challenges like uneven particle distribution and binder burnout.

Validation & Outcomes

  • Achieved uniform dispersion of metal powder in the polymer matrix, validated via scanning electron microscopy (SEM).
  • Confirmed sintering viability using thermogravimetric analysis (TGA), ensuring structural integrity for post-processing.
  • Demonstrated FDM’s potential to produce complex metal parts at a fraction of SLM/SLS costs, advancing accessibility to metal AM.

Technical Proficiencies

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. 

Research Impact

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.

Internship Experience: Mechanical Engineering Intern

Iran Air (Islamic Republic of Iran Airlines)

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:

Aircraft Structural Systems & Maintenance

Structural Analysis & Repair

  • Worked extensively on the fuselage, wings, landing gear, and tail assemblies, analyzing components such as stringers, longerons, and bulkheads for stress, fatigue, and corrosion.
  • Assisted in sheet metal repairs using aluminum, titanium, and composite materials, adhering to Structure Repair Manual (SRM) guidelines.
  • Observed critical repairs on pressure bulkheads and radome composites, learning non-destructive testing (NDT) techniques like tap testing to detect subsurface defects.

Landing Gear Systems

  • Studied hydraulic and pneumatic damping systems in landing gear, focusing on shock absorption and load distribution during takeoff/landing.
  • Participated in wheel and brake maintenance, including nitrogen tire inflation, rotor-stator alignment, and temperature/pressure sensor calibration.

Aerodynamic Components

  • Analyzed ailerons, flaps, and elevators for aerodynamic efficiency and mechanical integrity.
  • Supported inspections of wing assemblies, including fuel tank integrity checks and flap actuator alignment.

Workshop & Technical Training

Engine Shop

  • Assisted in disassembly/assembly of turbofan engines (e.g., General Electric CF6, Rolls-Royce TAY), focusing on compressor blades, combustion chambers, and bearing lubrication systems.
  • Reviewed Component Maintenance Manuals (CMM) for engine part replacements and tolerances.

Machine Shop

  • Operated CNC machining centers, EDM wire-cut machines, and lathes to fabricate precision aircraft components.
  • Gained proficiency in CAD/CAM software for prototyping and repair part production.

Sheet Metal Shop

  • Performed riveting, bending, and heat treatment of aircraft-grade metals using Kraft Formers and hydraulic presses.
  • Repaired fuselage skin panels and wing ribs, ensuring compliance with aerodynamic specifications.

Composite Workshop

  • Observed composite layup and repair techniques for radomes and structural components, emphasizing weight reduction and durability.

Compliance & Safety

  • Adhered to Airworthiness Directives (AD) and Service Bulletins (SB) to meet EASA and FAA standards.
  • Documented repair processes and part traceability using Aircraft Maintenance Manuals (AMM).
  • Collaborated with quality assurance teams to validate component integrity and safety protocols.

Skills Demonstrated

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.

Bachelor’s Project: Comprehensive Analysis of Aramid Fibers and Reinforced Composites

University of Tabriz, Faculty of Mechanical Engineering | Summer 2017

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.

Key Research Areas

Mechanics of Composites

  • Analyzed tensile strength, compressive behavior, and fracture toughness of aramid composites, comparing them with traditional materials (e.g., fiberglass, steel).
  • Modeled stress-strain relationships and failure mechanisms using advanced numerical methods.
  • Explored anisotropic properties and their impact on structural design in aerospace and automotive industries.

Material Science & Production

  • Studied synthesis of para-aramid fibers (PPD-T) via liquid crystalline polymer solutions and extrusion processes.
  • Evaluated fiber forms (yarn, roving, woven fabrics) and their suitability for applications like ballistic protection, pressure vessels, and reinforced plastics.
  • Investigated thermal stability (up to 425°C) and environmental resistance (moisture, UV, chemicals).

Advanced Applications

  • Assessed aramid composites in aerospace (honeycomb panels, fuselage components), automotive (brake systems), and civil engineering (earthquake-resistant structures).
  • Explored cost-benefit analysis of replacing traditional materials with composites for weight reduction and fuel efficiency.

Technical Contributions

Performance Optimization

  • Identified polyethylene and epoxy matrices as optimal for maximizing aramid fiber strength (3.6–4.1 GPa) while mitigating compressive buckling.
  • Validated material uniformity via scanning electron microscopy (SEM) and thermogravimetric analysis (TGA).

Innovative Solutions

  • Proposed hybrid composites (aramid/carbon fiber) to balance stiffness, toughness, and cost-effectiveness.
  • Highlighted aramid’s role in fail-safe structural designs, such as crashworthy aerospace components and impact-resistant body armor.

Skills Demonstrated

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.

Impact & Applications

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

Bachelor of Science in Mechanical Engineering (Manufacturing and Production)

University of Tabriz, Iran | Graduated: September 2017

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:

 Core Mechanical Engineering Fundamentals

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

Manufacturing & Production Specialization

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.

Practical Training & Projects

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

Additional Technical Proficiencies

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.