Institution: Khalifa University, Abu Dhabi
Duration: Sep 2024 – Present

Overview:

This project focuses on the design, fabrication, and characterization of large-scale composite metamaterials using carbon fiber–reinforced PLA and PPA polymers. Metamaterials are engineered structures with tailored mechanical and dynamic properties, which are not commonly found in natural materials. By leveraging advanced additive manufacturing techniques, this research explores how geometry, material composition, and scaling influence the performance of structural components.

Objectives:

• To fabricate large-scale metamaterial structures (gyroid and primitive lattices) directly via 3D printing

• To study the mechanical performance of structural elements such as cubes and beams under static and dynamic loading

• To understand the microstructural characteristics of printed composites and their effect on mechanical behavior

• To develop numerical models for predicting stress, deformation, and vibration responses of lattice structures

• To establish design–processing–property relationships for engineering lightweight, high-strength, and vibration-sensitive structures

Methodology:

• Design & Fabrication:
  Lattice structures including gyroid and primitive topologies were designed and directly 3D-printed using carbon fiber–reinforced PLA and PPA composites. Large-scale cubes and beams were produced to evaluate scalability and structural performance.

• Mechanical Testing:
  Quasi-static compression and flexural tests were conducted to assess strength, stiffness, energy absorption, and failure modes. The results provide insight into how lattice geometry and material reinforcement influence mechanical properties.

• Microstructural Characterization:
  Optical microscopy and scanning electron microscopy (SEM) were employed to examine fiber distribution, interlayer bonding, and printing defects, ensuring the quality and consistency of fabricated structures.

• Numerical Analysis:
  Finite element simulations were performed to predict stress distribution, deformation patterns, and failure mechanisms. Results were compared with experimental data to validate models and optimize structural design.

• Dynamic & Vibration Analysis:
  Static and dynamic analyses, including modal and frequency response studies, were conducted to evaluate structural stability, natural frequencies, and vibration behavior, critical for engineering applications requiring precision and durability.

Significance:

This project demonstrates the potential of additive manufacturing for high-performance composite metamaterials. The research provides a framework for designing lightweight, high-strength structures with tailored mechanical and dynamic properties, with applications in aerospace, automotive, robotics, and civil engineering. The insights gained also contribute to the development of predictive models for metamaterial performance, bridging the gap between material science, mechanical engineering, and computational design.

Future Work:

Future directions include optimization of lattice geometries, exploration of new composite materials, and integration with machine learning models to predict performance for large-scale engineering applications.

Institution: Khalifa University, Abu Dhabi
Duration: Feb 2020 – Jun 2024

Overview

This project focuses on the additive manufacturing, characterization, and modeling of NiTi (Nickel-Titanium) shape memory alloys, with an emphasis on Triply Periodic Minimal Surface (TPMS) structures. NiTi alloys exhibit unique shape memory and superelastic properties, making them valuable for advanced engineering applications. The work combines experimental fabrication, microstructural and mechanical characterization, and constitutive modeling to understand material behavior under various thermal and mechanical conditions.

Objectives

• Fabricate NiTi alloys and TPMS structures using Laser Powder Bed Fusion (LPBF)

• Perform microstructural, thermal, and mechanical characterization of fabricated samples

• Develop constitutive models to predict material response, including fatigue and failure criteria

• Generate data-driven insights for material optimization and publication

Methodology

• Additive Manufacturing: 3D-printed NiTi samples and TPMS structures using Laser Powder Bed Fusion (LPBF), optimizing printing parameters for structural integrity

• Characterization: Conducted extensive analysis using SEM, TEM, XRD, AFM, DSC, and fatigue testing to examine microstructure, phase composition, surface morphology, thermal behavior, and mechanical properties

• Modeling & Simulation: Performed numerical simulations and constitutive modeling to analyze experimental data, predict material behavior, and establish fatigue failure criteria

• Research Outputs: Published novel findings in peer-reviewed journals, contributing to the field of additive manufacturing and smart materials

Key Skills & Tools

• Additive Manufacturing (LPBF)

• Materials Characterization (SEM, TEM, XRD, AFM, DSC)

• Mechanical Testing and Fatigue Analysis

• Constitutive Modeling and Simulation

• Data Analysis and Scientific Computing

Impact

• Advanced understanding of NiTi alloy behavior in 3D-printed structures

• Developed predictive models for fatigue and failure in shape memory alloys

• Contributed to the design of high-performance, smart materials for engineering and biomedical applications

• Enabled publication of high-impact research articles demonstrating innovation in additive manufacturing of smart alloys

Institution: CSIR Advanced Materials and Processes Research Institute (AMPRI), Bhopal
Duration: Jun 2013 – Aug 2019

Overview

This project focused on the development of copper-based shape memory materials with enhanced mechanical properties, high transition temperatures, and cost-effective production in the form of wires and strips. Conducted as part of the 12th Five Year Plan of the Government of India, it was a collaborative effort between CSIR, New Delhi, and CSIR-AMPRI. The work aimed to design thermo-responsive and magnetic shape memory materials and devices for advanced engineering applications.

Objectives

• Develop copper-based alloys with superior shape memory and mechanical properties

• Optimize alloy compositions, heat treatment cycles, and secondary deformation methods

• Fabricate wires and strips suitable for engineering applications

• Perform microstructural, thermal, and mechanical characterization to understand material behavior

• Publish findings and establish collaborations for further research

Methodology

• Literature Review & Gap Analysis: Conducted extensive review to identify knowledge gaps and devise experimental strategies

• Alloy Fabrication: Synthesized alloys using vacuum induction melting furnace and applied secondary deformation techniques such as hot rolling and tensile processing

• Characterization Techniques:

  • Microstructural: Optical Microscopy, SEM, FESEM

  • Mechanical: Vickers Hardness, tensile testing

  • Chemical & Phase Analysis: Optical Emission Spectroscopy, XRD

  • Thermal: Differential Scanning Calorimetry (DSC)

• Data Analysis: Experimental results were systematically analyzed to correlate alloy composition, processing, and performance

Key Outcomes & Impact

• Published five research articles in SCI journals and delivered oral/poster presentations nationally

• Established collaborations with IIT Madras for materials research

• Developed thermo-responsive and magnetic shape memory materials suitable for engineering devices

• Contributed to cost-effective production methods for Cu-based shape memory wires and strips

• Positive reception of research presentations and recognition of project significance in national forums

Institution: Rajiv Gandhi Prodyogiki Vishwavidyalaya (RGPV)
Duration: Jan 2012 – May 2012

Overview

This project focused on biomass gasification as an alternative energy source. Locally available biomass wastes, including subabool woods, cow dung, wheat straw, and rice husks, were used to produce producer gas suitable for internal combustion engines. The study aimed to analyze the composition and quality of the producer gas and evaluate the potential of these biomass sources for future energy applications.

Objectives

• Utilize locally available biomass wastes for sustainable energy production

• Produce and analyze producer gas for engine applications

• Explore the feasibility of biomass energy as a renewable alternative

• Gain hands-on experience in energy systems, teamwork, and practical problem-solving

Methodology

• Collected and prepared biomass feedstocks (subabool wood, cow dung, wheat straw, rice husks)

• Conducted gasification experiments to produce producer gas

• Measured and analyzed the composition and calorific value of the gas

• Engaged with local vendors and stakeholders for sourcing materials and practical implementation

Key Outcomes & Learning

• Produced promising producer gas with potential for internal combustion engines

• Gained experience in teamwork, industrial collaboration, and conflict resolution

• Developed an entrepreneurial mindset by exploring commercial applications of biomass gasification

• Identified future possibilities for sustainable biomass utilization and energy research

Skills & Tools

• Biomass Gasification Techniques

• Renewable Energy Analysis

• Experimental Design & Data Analysis

• Teamwork and Industrial Collaboration