❖ Developing designs for electromechanical semiconductor wafer test probes used in IC chip testing❖ Preparing 3D CAD and performing non-linear FEA simulations in Solidworks to get tip force & maximum stress❖ Optimizing design based on FEA results ensuring conformation to proprietary MICA Freeform process capabilities❖ Generating drawings in Solidworks 2021, according to ASME Y14.5 GD&T standard, for client approval❖ Developing Product Specification documents and conducting Product Review Meeting with cross functional team members❖ Setting up the build for manufacturing, generating & verifying photomasks, and ordering them from suppliers to complete the mask tape-out process❖ Performing DFMEA to identify and address potential failures in manufacturing & testing at client side❖ Successfully completed prototype development of 16 probe needles, where I was also responsible for above activities and have handed them over to production for high volume manufacturing❖ Creating and verifying wafer design layouts, photolithography masks and interfacing with the production team for manufacturing hand-offs❖ Managing customer projects internally and reporting the manufacturing progress to customer and management❖ Writing technical reports for projects including statistical tolerance analysis to get stack-up tolerance for critical features having different materials in different layers

❖ Successfully generated FE model for Laser Powder Bed Fusion (LPBF) manufacturing process for multiple parts such as AlSi10Mg mount ring, Aluminum coin, and Polyamide 11 (PA11) Toy bricks and provided a valid solution for thermal distortion (NET shape), shrinkage, warpage, residual stress/strain, effects of heat-trapping, defects, and voids.❖ Successfully modeled FDM manufacturing process using FEA method for, Nylon12CF Bracket and ULTEM9085 channeled box and predicted distortion, warpage, waviness and manufacturing defects❖ Operated polymer 3D printer and designed manufacturing process (Slicing, G-code & support structure) for parts such as a chamber, mount ring, topology optimized bracket with generative design❖ Modeled and benchmarked commonly used materials in AM at room and elevated temperatures using cure kinetics; Polymers such as ABS, PA11, PA12, ULTEM1010, ULTEM 9085; Metals such as Inconel, Titanium, Aluminum, Stainless Steel & AlSi10Mg; Composites such as CF-PLA and Nylon12CF❖ Applied real-time multi-scale/multi-phase Thermal Management algorithm/code to show the stability of the printing process regarding the printing settings and successfully developed the process map for PA11 SLS & AlSi10Mg DMLS❖ Applied Design of Experiment (DoE) method to minimize thermal distortion of PA11 LPBF printed blocks and determine optimized laser power, scan speed, hatch-spacing & chamber temperature❖ Studied the variation of strength in ULTEM 9085 FDM printed dog bones in National Institute for Aviation Research (NIAR) database and calculated the strength allowable❖ Successfully validated load-displacement curves for the FE modeled ASTM E8, ASTM D638 – 14 tensile test & ISO 178 3-point bending testing procedures on DMLS printed AlSi10Mg, FDM printed ULTEM 9085 Dog bones, and CF-PLA test coupons

❖ Established a new method and prototype to use inorganic salts as binders for Jet Binder 3D printing of metals:❖ Performed comprehensive literature review and research about Metal Matrix Composites (MMCs)Manufacturing❖ Operated the process of binder jet3D printing on Titanium and Silicon Carbide❖ Material handling of titanium powder, phenolic resin, and silicon carbide❖ Operated hot Isostatic pressing furnace to heat treat the parts❖ Wrote the manual instruction of the 3D printer prototype including micro-stepper controller configuration with NEMA rotors and GUI interface of MACh3 software❖ Tested the printed parts at Instron Lab❖ Developed a 3D printer prototype for the project purpose❖ Determined the dominating factors in the curing process of the printed green parts by application of DoE methodhttps://pqdtopen.proquest.com/doc/2114870151.html?FMT=AIhttps://3dprint.com/238482/california-state-university-3d-printing-titanium-matrix-composites-ceramics/