Omar Elsayed Email & Phone Number

Mossville, Illinois, United States

Developing manufacturing automation solutions and providing consulting services to various teams around the company, including but not limited to: process automation, asset connectivity, process planning and new technology development, investigation and validation.

Cairo, Egypt

• Developed an ultra-lightweight, solar-assisted electric rickshaw, with the first prototype incorporating a 1.5kW dual-motor chain-drive powertrain coupled with a 4.6kWh LiFePO4 battery pack, capable of achieving a top speed of 40km/h and range of 100km for less than $1,700.• Developed an Arduino-based data acquisition module and testing suite to record real-time data of the electric vehicle’s battery voltage, current output, speed and incline angle to calculate its overall energy efficiency (measured in Wh/km) for subsequent prototype iteration efforts.• Designed a novel method for mounting a BLDC motor coupled with a manual transmission to the front wheel of a rickshaw, resulting in a simplified, more efficient and lower cost EV powertrain configuration.• Designed a low-profile cantilever suspension that allows for a simplified rear suspension system.• Performed an EV conversion on a rickshaw using a 1.5kW BLDC motor (directly coupled to the existingtransmission) and a 2.7kWh AGM battery pack, achieving a top speed of 30km/h and a range of 30km for $1,275.

Greater Atlanta Area

Thesis Title: Bead Geometry, Microstructure and Texture in Multi-Axis Directed Energy Deposition• Investigated the effect of non-orthogonal material deposition on laser attenuation extent, bead geometry, microstructure and texture in directed energy deposition processes.• Assisted in the material characterization of DED-processed 316L during an investigation of process parameter effects (laser power and powder feed rate) on the mechanical properties of SS-316L deposited material.• Deployed Industrial Internet of Things (IIoT) devices (Velocio PLC, Arduino) and communication protocols (Modbus, Firmata) to interface with the Moog Inc. Enterprise Network in a joint effort with the Georgia Tech Factory Information System’s Decoupled Architecture for IIoT.• Co-led the effort to bring the metallography laboratory up to the required performance, including material/chemical procurement, inventory updating and the development of standard operating procedures for metallographic practices within the laboratory.• Taught a sophomore-level mechanical design class (ME 2110 - Creative Decisions & Design), where 3 of 5 teams from my class section won 2nd, 3rd and 5th place in the Fall 2018 class-wide robotics competition comprising of 60 teams.

Mossville, Illinois, United States

• Developed a quick and efficient method to remove support structure material from metal 3D printed components, significantly reducing post-processing part costs and subsequent lead times.• Analyzed heat treatment process parameter effects on Ni-based alloy seal ring dimensional stability and residual stress distribution during a stress relief operation using isopleth/phase diagram calculations (via JMAT-Pro) and Six-Sigma investigative techniques• Provided a set of recommendations with regards to grinding process parameters and materials for minimum tool cost, minimized residual stress generation and optimum seal ring grinding quality.• Developed multiple universal fixture and work-holding mechanisms, including for: [1] Horizontal/vertical grinding of small/thin spectroscopy samples [2] Band-saw cutting of irregularly shaped large components in axial, longitudinal and lateral axes [3] Modular transportation fixture for large bulldozer idler systems to simplify logistics of transport [4] Multi-sample holder for full-immersion chemical etching (for improved etching effectiveness)• Supported the organization of the 2019 ASM Materials Summer Camp, and introduced high school students to the importance of materials science to sensor technology by exhibiting various demos and leading tutorials.

Dearborn, Michigan, United States

• Performed cell-level polarization testing (under various environmental conditions) on next generation Li-ion batteries for next generation electric vehicle programs.• Utilized legacy data to develop preliminary battery prediction modeling algorithms by determining optimum time exponent values via discharge capacity/energy throughput, resistance increases under various temperatures, charge depths, charge/discharge rates and their cumulative effect on capacity retention.• Communicated findings and recommendations to battery suppliers and design teams for enhanced battery performance and lifecycle optimization.

Greater Detroit Area

• Led efforts in resolving all powertrain related issues found on the shop floor, including engine, transmission, fuel and exhaust systems, driveline, cooling, powertrain controls/fluids/mounts and air induction systems.• Expedited parts sourcing, ordering, shipping and warehousing to ensure missing parts arrive to the floor promptly.• Fulfilled the requirements for engine complexity studies, reducing overall engine count to prevent assembly plant above-capacity conditions and potential plant expansions, saving the Company millions of dollars.• Developed a MATLAB algorithm that locates parts in inventories worldwide needed in future vehicle program builds, preventing part ordering redundancies and powertrain build costs by over $2 million.• Led benchmarking studies comparing future program powertrains with competitor powertrains to determine weight reduction opportunities and engage with the corresponding engineering teams to develop an execution plan.• Developed a MATLAB algorithm that detects and fixes part count and allocation discrepancies, with 10,000+ parts and 300+ vehicles being cross-checked, significantly reducing engineering and logistical labor time and expediting prototype build timelines.• Internal Awards: o Powertrain Recognition & Achievement Award

Greater Detroit Area

• Performed 3-point-bend testing (VDA-238-100), tensile testing (ASTM E8/E8M) and consequent material characterization to study bendability and tensile properties of TemperTough® AHSS alloys to determine material feasibility in energy absorption/ intrusion resistance applications on future vehicle programs.• Analyzed how the order of manufacturing processes affects crash test performance of AHSS crash cans to determine optimum production-intent manufacturing process conditions.• Research and developed testing methods for steel formability/bendability studies to expedite future material investigations.• Studied the effect of heat treatment schedules on inter-diffusion layer dynamics to understand coating thickness properties/performance on AHSS to determine optimum characteristics for intrusion resistance applications.

Greater Detroit Area

• Investigated the effect of constraint plate thermal mass and thermal conductivity on internal and external Li-ion pouch cell behaviors following exposure to atypical overcharging and abuse conditions.• Supported the validation of a high precision battery tester in a collaborative project with Arbin Instruments, Montana Tech, Sandia National Labs and the Department of Energy to prove enhanced and expedited battery life prediction capability. • Developed MATLAB algorithms to significantly increase data analysis rate for various tasks related to the project (>90% decrease in analyst labor time) as well as study the convergence nature of tester life-cycle prediction models.• Supported the design of experiments (DoE) of Li-ion thermal manifold flow channels to determine optimum pouch sealing resolution of integrated cooling flow channels and enhanced heat transfer geometries for future-generation battery technologies.• Internal Awards: o Ford Internal Recognition of Exemplary Teamwork o Ford Internal Recognition of Technical Innovation/Achievement• External Awards – Department of Energy: o 2016 R&D-100 Special Recognition Green Tech Merit Award – Precision High Power Battery TesterConference Papers / Presentations: • State of Overcharge: Lithium Ion Battery Abuse Response Phenomena in the Realm Beyond 100% in Automotive Applications – 2017 SAE World Congress • Quantitative Life Prediction Using High Precision Coulometry with Automotive Current Rates – 229th ECS Meeting

Greater Detroit Area

• Developed a battery enclosure concept using short-GF polyethylene composite to replace standard stamped steel options for future battery pack technologies (potential 85% weight reduction opportunity).• Co-developed a prototyping concept that significantly reduces labor time and cost for sheet-like components via vacuum thermoforming, while simulating injection molded material properties, with resultant reductions including >95% in prototype tooling cost and labor time.

Greater Atlanta Area

• Performed low frequency cyclic fatigue 4-point bending testing (ambient temperature) of fuel-grade Ethanol pipeline samples using 7 different frequencies over 3 timespans to determine the causes and reduce the effects of pipeline stress corrosion cracking.Conference Papers/Presentations:• Effect of Low-Frequency Cyclic Stresses on Stress Corrosion Cracking of Pipeline Steels in Fuel-Grade Ethanol –2016 PEERS

Greater Atlanta Area

• Performed bottom-up synthesis of silver nanoplates (used in biological and chemical imaging and sensing as well as metallic ink for printable electronics) with 50nm edge length.• Experimented different methods to optimize uniform thin film coatings on PS substrates for flexible electronics.

Master Of Science - Ms, Mechanical Engineering, Highest Honors

Major: Mechanical Engineering Research Area: Metal Additive Manufacturing

Bachelor’S Degree, Mechanical Engineering, Honors

Activities and Societies: Engineers Without Borders, Wreck Racing, American Society of Mechanical EngineersMajor: Mechanical Engineering.