Experiment Design Analysis to Minimize Variability of Injection Molded Precision Plastic Parts
January 2020 - May 2020

The project required the team to work with a local manufacturer who makes injection molded precision plastic parts to identify factors in the process responsible for variability in the part. The experiments were strictly constrained to 16 process runs per batch with a maximum of 100 runs.
We started with initial screening experimental design and ended up optimizing the process with response surfaces and central composite design. We also developed predictive statistical model based on previous injection molding operation data to predict the response of the process when selecting different combination of process parameters.

JMP  •  Design of Experiments (DOE)  •  Statistics  •  Injection Molding  •  Process Improvement

Development of New Electromechanical Product for Customer and Technological Investments
January 2020 - May 2020

This academic project was divided into two distinct projects: Product Development and Consultation and was meant to develop a thorough understanding of the product development process in detail for a single customer as well as a huge population.
Starting with the product development project, the first step in the process was to interview a probable customer and determine the requirements for the product they wanted. Following this, I used QFD for Customer Attributes and Technical Attributes, followed by functional diagrams of sub-systems along with brainstroming for mechanisms and developing system design variables. The project ended with Life Cycle Assessment (LCA) of the product with quantification of Use and Disposal phases.
The second research project was to consult a virtual global manufacturing firm. Our goal was to define the steps and technologies that they must start taking today, or invest in, so that they can be successful in the year 2035.

Product Development Process  •  Customer Requirements  •  QFD & House of Quality  •  Functional Diagrams  •  Brainstorming Techniques  •  Portfolio Development  •  Conjoint Analysis  •  Discrete Choice Analysis  •  Product Architecture & Platforms  •  LCA  •  Multi-attribute Decision Making  •  Failure Mode and Effect Analysis  •  Benchmarking

Statistical Analysis and Learning Models to Predict the Strength of Concrete Mixture
January 2020 - May 2020

This project allowed my team to use our knowledge of Statistics and Programming to predict the value of a response variable based on the given data. We used various regression methods such as, multivariate linear regression, box-cox transformation, ridge regression, best-subset selection, lasso regression, principal component regression, tree-based methods like the random forest, bagging, and boosting to perform statistical analysis and create a predictive mathematical model. The optimal model with relevant transformations had a Mean Square Error (MSE) of 5.0666.

Programming Language - R  •  Statistical Learning  •  Statistics  •  Data Analysis  •  Regression Analysis  •  Tree Based Models  •  Process Improvement

Powder Removal from Internal Cavities of a Part Manufactured by Electron Beam Fusion
January 2019 - May 2019

This was an unsupervised project with no instruction given on the working. I applied every concept involving Material Science and Metal Additive Manufacturing.
The project required a solution for the post-processing treatment of a high purity copper part manufactured using Electron Beam Fusion (EBF). We first segregated powder within the specified particle size for EBF by performing particle size distribution (PSD) analysis. Moreover, we used LECO Analysis to get assurance on purity of the feedstock. Next, we analyzed and deployed the optimum raster pattern to improve the material and structural properties of the component. Ultimately, a chemical etching process of copper using Cupric-Ammine complex ion as the etchant was suggested as the solution.

MATLAB  •  Additive Manufacturing  •  Electron Microscopy  •  Electron Beam Fusion  •  Chemistry  •  Material Science  •  Metallurgy  •  Finite Element Analysis (FEA): Thermal and Structural

Regulatory Compliance Audit and Corrective and Preventive Actions (CAPA) for Good Manufacturing Practices (GMPs) and Good Documenting Practices (GDPs)
January 2019 - May 2019

This project helped me develop an in-depth understanding of Regulatory Affairs for Medical Devices, Pharmaceuticals and Biologics.
I audited Golden LEAF Biomanufacturing Training and Education Center (BTEC) specifically for compliance issues with current Good Documentation Practices (cGDPs) and current Good Manufacturing Practices (cGMPs).

Medical Devices  •  Biologics  •  Pharmaceuticals  •  cGDPs  •  cGMPs  •  Global Regulations: CFR Title 21, EU - MDR, PDMA, ICH

Review and Analysis of Gelatin Methacryloyl (GelMA) as a viable component in 3D Culture Systems
September 2018 - December 2018

This was an independent group research project involving the concepts of Biomedical Engineering, Tissue Engineering, and Bio-3D printing/Bio Additive Manufacturing.
We researched about the derivation of GelMA as Hydrogel from Collagen and its nomenclature as Gelatin Methacrylate, Methacrylated Gelatin, Methacrylamide modified Gelatin, or Gelatin Methacrylamide in the industry. Then we compared it with collagen in antigenicity. We also studied its manufacturability, texture, 3D structure, porosity and emulation of native tissue. Finally, we decided on novel applications of GelMA in Tissue Engineering.

Biomedical Engineering  •  Additive Manufacturing  •  Tissue Engineering  •  Hydrogels  •  Chemistry  •  FDA Regulations  •  Patents

Effects of Binder Content on Machining Parameters Carbide Tools while Dry Turning
September 2018 - December 2018

We used concepts in Material Science and Advanced Machining to complete the project.
Analyzed the effect of cobalt content on Machining Forces, Surface Finish, and Tool Wear in Tungsten Carbide turning inserts while dry turning 1045 - Alloy Steel. I designed and manufactured a custom tool holder to accommodate the tool and piezoelectric load cell, and performed machining operations.
The results of the experiments established that the cobalt content is inversely proportional to the tool wear and surface roughness. This can be related to the difference in hardness of Cobalt and Tungsten Carbide.

Advanced Machining  •  Additive Manufacturing  •  Turning  •  Material Science  •  Metallurgy

Undergraduate Major Project - 3D Printed Models and Scaffolding for Biomedical Applications
December 2017 - June 2018

This project was done in collaboration with All India Institute of Medical Sciences and Jamia Millia under the supervision of Dr. Abid Haleem.
We extracted anatomical models of human skull from advanced imaging technique or computerized tomography (CT) Scan using 3D Slicer, Blender (Rendering) and Meshmixer (Printing Preparation).

Bioprinting  •  Additive Manufacturing  •  Rapid Prototyping  •  Biomechanics  •  FEA  •  CT Scan  •  Prosthetics  •  Implants

Undergraduate Minor Project - Product Design and Quality Inspection using Bespoke Tolerance Analysis
June 2017 - December 2017

This study was done under the supervision of Dr. Abid Haleem.
We researched the role of 3D Scanning in industrial application and product design. We as a team audited client facility to rectify quality challenges in flange nuts and designed sample precision components for Tolerance Analysis. For the major part of the process we implemented overhead Steinbichler Comet L3D scanner system to collect 3D point cloud images to reverse engineer nut design. Finally, we were able to perform tolerance analysis using Digital Image Correlation technique in Geomagic Control X and achieved results within 1% error range and 3 minutes faster inspection process per sample.

Quality Assurance  •  Lean Six Sigma  •  3D Scanning  •  Digital Image Correlation  •  Geomagic Control X  •  Process Improvement

ABU Robocon India 2017
September 2016 - March 2017

A team project for the annual national competition organized by Asian Broadcasting Unit (ABU). A common objective is provided for the competition and teams play 1-v-1 matches to win. In 2017 the objective was to create a robot which can throw a polystyrene disc and make it land on the platforms.
I led a cross - functional team of 21 undergraduates to design and develop the disc throwing robot and served as the Design Lead. I was responsible of designing the platform angle mechanism and its drivetrain and performed Computational Fluid Dynamics (CFD) on the disc to optimize designs. I also managed administration and budgeting.

Robotics  •  Arduino Programming  •  MATLAB  •  Drivetrain  •  CFD  •  Project Management  •  Budgeting  •  Leadership

Shell Eco-Marathon Asia 2016
August 2015 - March 2016

Our team project for the annual intercontinental competition organized by Royal Dutch Shell where efficient cars race to win the title of Most Efficent in two different vehicle categories, further divided into different fuel types. Team JMI Supermileage fabricated an Urban Concept Vehicle (named CRUX) running on 50cc gasoline engine with a recorded mileage of 80 km/L.
I designed the hull and transmission system using Solidworks, a Computer Aided Design (CAD) Software. I also optimized the positioning of vehicle systems to improve safety and drivability.

CAD  •  Automotive Engineering  •  Solidworks  •  Drivetrain  •  Transmission System  •  Leadership

Other Team Members:  Abhishek Goyal  |  Tarbiya Khan  |  Puneet Malhotra  |  Zishan Ahmad  |  Spandan Rohilla  |  Kashan Khan