Mechanical Engineer Assistant
Resume:
Ali Abbas
Fort Collins, CO, US 80524
********.****.***@*****.***
linkedin.com/in/ali-abbas-b8931ba2
SUMMARY
I am a Mechanical Engineer with an ambition to become part of a company working on the cutting-edge technology. My 5 years of experience as a practicing engineer combined with a 3 years’ experience of Soft Robotics research & development makes me particularly well-suited to work closely with my team members to best understand the technical needs of the task at hand and effectively translate them to reality. My diverse engineering background testifies my ability to learn new things swiftly and correctly.
EDUCATION
1.MS. MECHANICAL ENGINEERING COLORADO STATE UNIVERSITY AUG 2015 TO MAY 2018
Major Projects:
Evaluated the task level robot control method for the first three joints of PUMA 560 robot using Matlab (Simulink).
Solved conjugate heat transfer problem of series of electronic chips using ANSYS Fluent.
3D Multi-Material Printing of robotic manipulators and molds used to fabricate soft robots.
2.BS. MECHANICAL ENGINEERING UNIVERSITY OF ENGINEERING & TECHNOLOGY LAHORE PAKISTAN 2010
Senior Design Project:
Design and testing of pressure vessels and performing simulations using PVElite.
Skills & Abilities
1.ENGINEERING:
Soft Robotic Design
Rapid Prototyping
3D Modeling & Printing
High Pressure & Gravity Die Casting
Electro-Mechanical Design
3D Assembly & Simulation
Injection Molding
Structural Analysis
Design for Manufacturing
Product Life Management
CFD & FEA
GD&T
Thermal Analysis
On-board Sensing
CNC Machining
Product Development
2.SOFTWARE:
Solidworks
PTC (Creo, Windchill)
AutoCAD
Arduino Programing
Minitab
MatLab
Simulink
Python & C++
ANSYS (Fluent, Icepack)
LabVIEW
3.LEADERSHIP:
Served as President of Pakistani student organization (Pak Rams) at Colorado State University, 2016.
Worked as Deputy Director Graduate Affairs for the Associated Students of Colorado State University, 2017.
EXPERIENCE
1.RESEARCH ASSISTANT (SOFT-ROBOTICS) COLORADO STATE UNIVERSITY OCT, 2015-PRESENT
Designed, fabricated and tested (e.g. stress, thermal, bending etc.) novel soft robotic and soft actuation systems.
Developed a new Soft Artificial Muscle actuator for the actuation of soft robotic systems.
Performed design optimization and process improvement to improve the efficiencies of the actuation system
Tested different materials e.g. EcoFlex 0010-30, Proto Pasta, PLA etc. to specify best properties for soft actuation.
Created an on-board self-sensing system for the shape estimation and feedback control of soft robots.
Designed experimental setups to test and validate mechanical and electrical properties of soft compliant composites.
Used and improved novel rapid manufacturing and casting techniques to make soft robots more efficient.
Constantly learned about soft active materials and soft actuation techniques and applied them to new soft robots.
Performed statistical tolerance analysis and GD&T to ensure smooth assembly of robots.
Conducted thermal analysis to analyze the design of robotic systems using ANSYS Icepack.
Mathematically modeled static and dynamic actuation response of soft actuators using Matlab and Python
Major Projects:
1.Developed a low-cost soft sensor for the control of soft robots.
A new soft-sensor was developed and its ability for self-sensing was successfully tested by embedding it in soft robots.
2.Designed and manufactured a novel soft-robotic fish-tail.
This robot was actuated by soft actuators and could mimic the complex 3D motion of fish-tail under water.
3.Established a physics base mathematical model to estimate the actuation response.
Model was developed to estimate the static and dynamic response of soft artificial muscle actuators.
4.Designed and created test rigs to test and validate soft robots and actuators.
Four test rigs were designed and developed to test the performance of the soft robots and actuators.
2.TEACHING ASSISTANT COLORADO STATE UNIVERSITY AUG, 2016-DEC, 2017
Taught MECH-402: Mechanical Engineering Experimental Analysis in Fall 2016 & 2017.
Taught MECH-338: Thermal/Fluid Sciences Laboratory in Spring 2017.
ENGINEER OPERATIONS SUI NORTHERN GAS & PIPELINES LTD, PAKISTAN APR, 2012-AUG, 2015
Team-lead natural gas metering and pipeline operations. Core job was to ensure uninterruptable gas supply.
Managed the pipeline fabrication shop where I created shop floor crew plans to ensure effective allocation of resources.
Design for fabrication and installation of new regulating stations at upstream of directly fed network.
Natural gas distribution network and pipeline infrastructure development at large scale.
Performed critical path methodology to estimate the completion time for each task.
Designed and ensured operation of pipeline network and regulating stations as per ASME B31.8 code.
Performed detailed assessments and material testing for new designs of pipeline and regulating station assemblies.
Supervised the testing, installation and maintenance of measurement gadgets at metering stations.
Major Projects:
1.Designed and supervised installation of new TBS/DRS at the upstream of high pressure areas.
25 new stations were installed. Hook-ups of new stations were managed in a way that the gas supply is not interrupted.
2.Reduced natural distribution losses for 13% to 6%.
By improving pressure regulation through TBS/DRSs maintenance and optimal pressure settings losses were reduced.
3.Effective vigilance of high consumption commercial tariff consumers.
High volumes of natural gas were recovered by converting fixed factor billing to EVC billing.
4.Implemented HAZOP and on job training of Health Safety and Environment.
No accident reported for three consecutive years because of training and implementation of safety standards.
ASSISTANT MANAGER PRODUCTION ATLAS HONDA LTD, PAKISTAN APR, 2010-APR, 2012
Ensured smooth mass production of High Pressure Die-Casted (HPDC) aluminum engine covers, Gravity Die-Casted (GDC) suspension parts and Injection-Molded cosmetic parts of Honda motorbikes.
Planned and implemented quality inspection of sampled production and rectification of defects identified.
Led the DFM process and re-programed the casting machines to produce new model engine parts.
Planned and executed HPDC and GDC die-rotation plan to produce 500K motorbikes per year.
Managed all the Quality Management System documents e.g. SOPs, BOMs, drawings, training material etc. to ensure successful ISO 9001-2008 internal and external audits.
Developed new quality inspection tools in collaboration with CNC machining department (Our in-house customer).
Led small group activities like Quality Control Circle (QCC) to continuously improve production quality and capacity.
Major Projects:
1.Capacity Enhancement of the casting plant from 500K to 650K per year.
Oversaw the entire project from machine layout to the installation and final commissioning of new machines.
2.Localization of HPDC casting molds and mold spares for Honda motorbike engine covers.
Collaborated with vendors and achieved cost effective localization of molds which helped to cut down the cost of importing the molds from SHOWA CO. Japan.
3.Rectified the heat exchange problem of Honda CG 125’s engine cylinder HPDC mold.
ANSYS Fluent was used to simulate and rectify improper heat exchange of the mold.
4.Redesigned an obsolete HPDC mold for EURO 2 Honda CG 125 Model.
Led the team to win the quality circle competition by redesigning the obsolete mold to meet the model change.
Publications
Title
Authors
Conference
1. Twisted and Coiled Sensor for Shape Estimation of Soft Robot
Ali Abbas & Dr. Jianguo Zhao
IEEE: IROS, 2017
2. A Physics Based Model for Twisted and Coiled Actuator
IEEE: ICRA, 2017
3. A Low-Cost Soft Sensor for Soft Robots
ASME: DSCC, 2016
References
Shall be furnished as per requirement.
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