Studying the process-microstructure-property-performance linkage in metal AM and synthesizing knowledge from in-situ monitoring, finite element method, topology optimization & deep learning to improve design outcomes.• Developed a data-driven topology optimization incorporating in-situ monitoring data from LPBF (EOS M290 using PrintRite3D®) to improve select performance criteria for AM parts• Developed a novel computational methodology to address effect of local thermal accumulation in LPBF by combining AM process simulation, topology optimization and lattice structure optimization• Developed deep learning-based surrogate models to predict part temperature built by DED and predict meltpool temperatures in LPBF• Developed LPBF and DED thermo-structural finite element (FE) codes using commercial codes to analyze the print process of metal AM• Employed Design of experiment (DOE) strategies to explore process parameter space of metal AM • Analyzed failure mechanisms (FEMA) and addressed issues in 3D printed structures with complex material composition including optimized 3D printed plastic (ABS, PLA) and metal (AlSi10Mg, In625, Ti6Al4V)• Developed design optimization workflows for design for additive manufacturing of leading aerospace company on bracket and reduce weight by 30% and improved mechanical performance by 20%• Studied mechanical response of knitted textiles FE codes in high-performance computing setup• Developed workflows to segment fiber orientations for CT scans of fiber-reinforced composites

1. Mechanics of Vibration, 2. Applied Engineering Analytical & Numerical Methods 3. Statics4. Freshman Design coursesTools taught: Abaqus, Creo Parametric, MATLAB, Python, Fusion 360, Python, SolidWorks

• Developed computational models for crystal plasticity using user subroutines to study the effect of crystal plasticity • Employed Abaqus in-built extended Finite Element Method and other fracture models to study particle fracture• Developed models coupling non-linear implicit Finite element formulation with explicit dynamic finite element formulation to study the resultant elastic wave propagation in dual-phase metal microstructure for Structural Health Monitoring.

1. Fundamentals of Computer-Aided Design - Instructing lab sessions of AutoCAD 2016 and Creo 3.0; grading assignments2. Experimental Mechanics -Conduct lab sessions; grade pre-lab assignments and lab reports

• Led product design from ideation to prototyping; experienced in a range of metals and ceramics• Performed static, dynamic structural & thermo-mechanical analyses to identify potential failure• Use of multi-body analysis for capturing dynamic loads of mechanical subsystems for FE analysis• Optimized sensor placement using design optimization for passive monitoring of architectural beams• Proposed design changes in labial orthodontic implants based on FE simulations of maxillary anterior teeth using micro-implants & intrusion arch based on moment loadsSoftware

• Conceptualized design for mechanical systems based on design for manufacturing (DFM), Design for Assembly (DFA) and Design for Six Sigma (DFSS) practices and ISO standards• Deployed drawings for precision manufacturing using geometric dimensioning & tolerance analysis• Analyzed and rationalized design of existing products to improve performance & efficiency using stress analysis and proposed alternate materials ranging from specialized alloys to polymers• Cost and manufacturing process optimization with cost and time constraints• Developed product designs to be manufactured using die and investment casting, sheet metal forming, and injection molding

• Instructing students and industry professionals in AutoCAD, Pro/Engineer Wildfire 4.0, CATIA, NX and SolidWorks 2012, ANSYS and Primavera.