Shahadat Hussain, PhD

1. Metamaterial Composites & Green Steel AM: Specialize in carbon/glass fiber-polymer metamaterial composites and green steel additive manufacturing using Fused Filament Fabrication (FFF) for heavy structural parts.

2. Additive Manufacturing: Expert in FFF, SLM/LPBF (NiTi TPMS lattices), SLA, PolyJet; hands-on with Raise3D, Formlabs, Stratasys, Bambu Lab Carbon X1 and EOS M400.

3. Characterization Equipment: Proficient with JEOL/FEI Quanta 3D FIB, Nova NanoSEM (SEI/BSE/EDS), Bruker D2 & Rigaku MiniFlex XRD, Leica microscopy, Mettler Toledo/Setaram DSC.

4. Mechanical Testing & Processing: Skilled in Instron tensile/compression/fatigue testing; experienced in vacuum induction melting, hot/cold rolling, heat treatment, quenching, metallography, etching.

5. Education & Skills: PhD in Materials Science & Technology, BEng in Mechanical Engineering. Published on Cu-based shape memory alloys; teaching experience; strong in data analysis, teamwork, project management.

Sep 2024 - Present

Division of Engineering

New York University Abu Dhabi | ROR ID

Abu Dhabi, United Arab Emirates (UAE)

✔️ Developed Fused Filament Fabrication (FFF) processes for carbon fiber and glass fiber-reinforced polymer composites (PPA, PLA, ABS, Vetrowhite, Nylon) using the Raise3D Pro3 Plus HS printer.

✔️ Manufactured complex TPMS-based metallic metamaterials (cubes and beams) via hybrid route: Stereolithography (SLA) wax-resin patterns on Formlabs Form 3, followed by gypsum investment casting and aluminum alloy pouring.

✔️ Produced "green steel" TPMS structures by 3D printing stainless steel-polymer filaments on Raise3D Forge1, followed by debinding and sintering.

✔️ Scaled large-format TPMS beams through hybrid SLA-pattern + sand/clay casting techniques.

✔️ Fabricated Interpenetrating Phase Composites (IPCs) with TPMS architectures using different resins for structural strength and vibration absorption.

✔️ Performed four-point bending tests on IPC and non-IPC beams to evaluate flexural strength, rigidity, deflection, and stress distribution. Conducted compression testing on TPMS cubes to analyze elastic modulus, yielding behavior, plateau region, densification, toughness, resilience, and energy absorption.

✔️ Explored robot arm-assisted Direct Energy Deposition (DED) for large-scale metallic structure fabrication.

This role has enhanced my expertise in multi-material additive manufacturing, hybrid processing, and mechanical characterization of advanced architected materials.

#AdditiveManufacturing #Metamaterials #3DPrinting #MaterialsScience

Feb 2020 - June 2024

Mechanical Engineering

Khalifa University | ROR ID

Abu Dhabi, United Arab Emirates (UAE)

✔️ Conducting an extensive review of the existing literature on additive manufacturing (3D printing) techniques for NiTi/nitinol shape memory alloys, focusing particularly on laser powder bed fusion (LPBF) methods, such as Selective Laser Melting (SLM). 

✔️ Examining and characterizing the properties of additively manufactured NiTi triply periodic minimal surface (TPMS) structures, specifically Schwartz primitive and Schoen gyroid lattices, which belong to the category of porous, cellular, and architected materials.

✔️ Performing tensile and fatigue tests on thin NiTi wires with different diameters, chemical compositions, and surface treatments (including etched, mechanically polished, etched polished, and light oxide coating) using an Instron 8872 fatigue testing machine.

✔️ Utilizing hydrofluoric and nitric acids for chemical etching of NiTi samples.

✔️ Applying various analytical techniques such as optical microscopy, SEM (Scanning Electron Microscopy), XRD (X-ray Diffraction), EDS (Energy-Dispersive X-ray Spectroscopy), metallography, heat treatment, EBSD (Electron Backscatter Diffraction), AFM (Atomic Force Microscopy), and EBSD for the investigation and analysis of the materials.

✔️ Proficient in various software applications including Xpert HighScore Plus, ImageJ, Origin, microscope image analysis software like Gatan suite, FreeCAD, programming languages such as Python, and word processing tools like LaTex. 

✔️ Contributing to the field through research article publications and conference presentations.

#AdditiveManufacturing #3DPrinting #LaserPowderBedFusion #NiTi #ShapeMemoryAlloys #TPMS #Metamaterials #DataAnalysis #ResearchPublications #FatigueTesting

Jun 2013 - Aug 2014

Department of Smart and Functional Materials 

CSIR-Advanced Materials and Processes Research Institute (AMPRI) 

CSIR - ROR ID  |  AMPRI - ROR ID

Bhopal, Madhya Pradesh (MP), India

✔️ During my tenure as a researcher at CSIR-Advanced Materials and Processes Research Institute, I gained valuable experience in various aspects of the scientific research process. This included making scientific observations, conducting experiments, formulating hypotheses, collecting and managing data, performing data analysis, fostering teamwork and collaboration, utilizing creative problem-solving skills, and effectively communicating both orally and in written form. Additionally, I developed skills in building relationships with other institutes and suppliers, as well as negotiation skills.

✔️ One of the significant projects I worked on was titled "Design and Development of Thermo-responsive and Magnetic Shape Memory Materials and Devices for Engineering Applications," which was part of the five-year plan of the Government of India. The project was sponsored by the Council of Scientific and Industrial Research in New Delhi.

✔️ Within the scope of this project, I engaged in experimental work that encompassed various tasks. These included the synthesis of alloys through vacuum induction melting, conducting standard metallography procedures, performing heat treatment processes, and characterizing the materials using techniques such as optical emission spectroscopy, optical microscopy, scanning electron microscopy, x-ray diffractometry, differential scanning calorimetry, hardness testing, tensile testing, and hot rolling.

✔️ The outcomes of my research efforts resulted in the publication of five research articles in respected SCI journals. Additionally, I had the opportunity to present my findings through poster and oral presentations. Furthermore, I collaborated with the Metallurgical and Materials Engineering department at the Indian Institute of Technology, Madras, enhancing the interdisciplinary nature of my research endeavors. 🤝

#Cu-Al-Ni #Cu-Al-Mn #InductionMelting #ShapeMemoryAlloys #SmartMaterials #MaterialsCharacterizations #MechanicalTesting #Collaboration #TeamWork #TechnicalWriting

Sep 2012 - May 2013

Mechanical Engineering

Oriental Group of Institutions

Bhopal, Madhya Pradesh (MP), India

✔️ I played an active role in both teaching and management during my time as an educator. I was responsible for instructing students in various mechanical engineering subjects, catering to first, second, and third-year engineering students. This experience allowed me to develop a strong foundation in materials science, machine component design, strength and mechanics of materials, and basic mechanical engineering concepts. Additionally, I facilitated laboratory activities to enhance the practical understanding of the students.

✔️ I actively participated in a two-week ISTE workshop on Engineering Thermodynamics, which was organized by the Indian Institute of Technology Bombay. This workshop provided me with valuable skills, including classification techniques, strategies for solving numerical problems, and effective methods of presenting technical information.

✔️ I received positive feedback from students regarding my lectures, successfully completing the syllabus within the designated time frame. I encouraged students to strive for academic excellence and supported their efforts to improve their semester results. By fostering a warm and supportive environment, I was able to establish strong relationships with the students, creating a conducive learning atmosphere.

#Teaching #MachineComponentDesign #EngineeringMaterials #Thermodynamics #BasicMechanicalTesting #Mentoring #Lab

Jun 2011 - Jul 2011

Bokaro Steel Limited, Steel Authority of India Limited (SAIL) | ROR ID

 Bokaro Steel City, Jharkhand, India

✔️ I underwent a comprehensive two-week industrial training program at SAIL-Bokaro, located in Bokaro Steel City, Jharkhand, India. During this training, I gained practical knowledge and hands-on experience in various departments and facilities.

✔️ Specifically, I received training and insights into the operations and processes of Coke Ovens, Blast Furnace, Machine Shops, Foundry Shop, Steel Melting Shop, Continuous Casting Shop, Hot Rolling Mill, and Cold Rolling Mill. This immersive experience allowed me to understand the intricacies and functioning of each area, providing valuable exposure to the steel manufacturing industry.

#BlastFurnace #Metallurgy #OreExtraction #SteelMaking #Rolling #SteelAuthorityofIndia #IndustrialTraining

Materials Science and Technology

Aug 2014 - Jul 2019

Academy of Scientific and Innovative Research, CSIR-AMPRI | ROR ID

Bhopal, Madhya Pradesh (MP), India

✔️ My doctoral research focused on investigating the impact of grain refiners, alloying additions, and processing parameters on the behavior and shape memory properties of Cu-Al-Ni shape memory alloys for high-temperature applications.

✔️ The research encompassed various stages, including the synthesis of alloys using vacuum induction melting, heat treatment, and quenching, as well as hot rolling. Extensive sample preparation and metallography were conducted, utilizing both manual and automatic grinding and polishing techniques. Characterization involved the use of optical microscopy, scanning electron microscopy, X-ray diffractometry, and differential scanning calorimetry. Mechanical testing, such as tensile testing at different temperatures, compression testing, and hardness testing, was performed. The evaluation of shape recovery and other functional properties employed improved testing methodologies. 

#Cu-Al-Ni #ShapeMemoryAlloys #InductionMelting #AdvancedMaterials #SmartMaterials #MaterialsCharacterizations #MechanicalTesting #HighTemperature #PhD #Thesis #MaterialsScience 

Mechanical Engineering

Aug 2008 - Jun 2012

UIT, Rajiv Gandhi Proudyogiki Vishwavidyalaya (RGPV) | ROR ID

Bhopal, Madhya Pradesh (MP), India

✔️ Completed a two-week industrial internship during my third year at Bokaro Steel Plant, which is part of Steel Authority of India.

✔️ Conducted a major project on biomass gasification as an alternative energy source for internal combustion engines and turbomachines.

✔️ During my studies, I acquired technical knowledge in various areas, including machine component design, thermal sciences related to power plants, IC Engines, air conditioning and refrigeration, fluid and turbo-machinery, production and industrial engineering, as well as concepts of operation management and entrepreneurship.

#BachelorOfEngineering #MechanicalEngineering #RGPV #IndustrialTraining

10‑week teaching certificate course, Center for Teaching and Learning (CTL) department, Khalifa University 2023

• Effective teaching strategies

• Assessment techniques

• Ethics, professionalism and boundaries 

• Educational technology tools 

• Active learning and course alignment

• Classroom dynamics 

• Intercultural communication, and gender communication styles

• Micro-teaching sessions

Lab Safety Courses, Khalifa University, Abu Dhabi 2021

• Ergonomics

• Emergency Response

• Waste Management

• Chemical Safety

• Fire Safety

• Risk Assessment

• Electrical and Radiation Safety

• Cryogenic Substances

• Ventilation

• Personal Protection Equipment

• Hydroflouric Acid Handling for Chemical Etching of 3D Printed NiTi Samples

Collaborative Institutional Training Initiative (CITI) Program Florida, US, 2020 Course Learner Group of Engineering and Computing RCR

• Introduction to RCR

• Research Misconduct

• Data Management

• Conflict of Interest

• Collaborative Research

• Authorship

• Plagiarism

• Research Involving Human Subjects

• Surveying

• Questionnaire Design

• Consulting Village Head and Land Officer (Patwari) 

• Data Collection

• Data Analysis

• Team work

• Report Generation

• Materials Science and Engineering

• Scientific Ethics, Technical Communications and Safety

• Characterization and Analytical Techniques

• Heat Treatment

• Tribology ‑ Science and Practice

• Phase Transformation

• Lightweight Materials

• Powder Metallurgy

• Composite Science and Engineering

• Nano Science and Engineering

• Materials Synthesis and Processing

• Computer Simulation and Design

• Functional and Smart Materials

• Cellular Materials