Hi, my name is Atyab Azhar and as a mechanical design engineer, I specialize in creating innovative designs using AI-assisted design tools and advanced manufacturing techniques. I have experience working in industries such as power, automotive, and robotics, and am well-versed in CAD software, FEA, and other engineering tools.
Clients: Work Portfolio, volunteer work and freelancing projects.
Date : 2017 to Present
I am a skilled Mechanical Design Engineer with over four years of industry experience, specializing in various aspects of mechanical design and development. My portfolio spans multiple projects where I have extensively worked on sheet metal design, automotive and robotic harnesses, and weldments. I am proficient in developing IP rated enclosures and PCBA packaging inside metallic enclosures. My proficiency extends to designing Electric Vehicle (EV) chargers, creating intricate assemblies, and shaping plastic molded parts.
Familiar with global standards, I apply ISO tolerances and stack-up tolerances to maintain design integrity and ensure product quality. My design methodology is a fine balance between functionality and manufacturability, considering factors such as tolerance fitting conditions, geometric tolerances, and dimensional tolerances, all of which contribute to efficient, effective, and error-free designs.
In the realm of EV charger design, I’ve implemented standards such as SAE J1772 and IEC 62196, demonstrating adaptability to different international practices. These rigorous standards ensure the products are safe, reliable, and compatible with a wide array of electric vehicles.
My work in sheet metal design employs DIN 6935 for bend allowance calculation, while for plastic part design, I utilize UL 94 for flammability testing and ASTM D638 for tensile properties evaluation. When designing enclosures, I adhere to the IP Code (IEC 60529) to define levels of sealing effectiveness against intrusion from foreign bodies (tools, dirt, etc.) and moisture.
My experience with harness design involves using IPC/WHMA-A-620 standard for cable and wire harness assemblies, ensuring quality and reliability. I am well-versed with the design and development of robotic systems, including understanding of ISO 10218 for robot safety.
From concept to completion, I apply practical and theoretical knowledge, taking into account material properties, environmental conditions, functional requirements, and manufacturing processes to create innovative and efficient designs. Whether working on small components or complex systems, my goal remains the same: to deliver high-quality, cost-effective, and sustainable solutions that meet the demands of the modern world.
As I conclude my mechanical design portfolio, I reflect on the diverse experiences and robust skills I’ve acquired throughout my career as a Mechanical Design Engineer. However, I firmly believe in the ethos of lifelong learning. I’m driven by an innate curiosity and the quest for continuous improvement, both professionally and personally. To this end, I am keenly interested in advancing my expertise through graduate studies. I see this as an opportunity to delve deeper into the intricacies of mechanical design, explore emerging technologies, and challenge myself within a rigorous academic environment. My commitment to expanding my knowledge and skills will not only enhance my capabilities but also bring innovative solutions and value to future engineering challenges.
P.S: In my free time, my creative side takes over as I design non-fungible tokens (NFTs) for various clients, adding a unique dimension to my professional persona and fueling my passion for design in the digital realm.
Clients: Work Portfolio, volunteer work and freelancing projects.
Date : 2019 to Present
Beyond design, my focus has been on diverse facets of engineering simulations and modeling. My portfolio encompasses various projects where I have rigorously worked on Finite Element Analysis (FEA), Computational Fluid Dynamics (CFD) simulations, and heat transfer studies. I am adept at performing stress-strain analysis and thermal studies inside complex systems. My expertise further extends to analyzing intricate assembly interactions, and modeling the behavior of injection-molded parts.
Adhering to international norms, I apply ISO standards and sensitivity analysis to uphold simulation accuracy and ensure optimal results. My simulation methodology maintains a delicate equilibrium between real-world representation and computational feasibility, considering factors such as boundary conditions, mesh quality, and solution convergence, all of which lead to precise, efficient, and error-free models.
My work with structural simulations employs DIN 15018 for stress classification, while for plastic part simulations, I utilize ISO 294 for simulation of injection molding and ISO 178 for flexural properties assessment. When conducting thermal studies, I stick to the ISO 10211 to define levels of thermal bridges in building envelopes.
My experience with CFD simulations involves using ISO/TR 11146 for laser beam simulations, ensuring accuracy and trustworthiness. I am conversant with the simulation and assessment of robotic systems, including understanding of ISO/TS 15066 for collaborative robot systems.
From model creation to result interpretation, I apply pragmatic and theoretical knowledge, taking into account material properties, operational conditions, functional requirements, and manufacturing implications to develop insightful and effective simulations. Whether working on individual components or complex systems, my goal stays unchanged: to deliver high-quality, cost-efficient, and sustainable solutions that meet the requirements of the contemporary world.
As I summarize my engineering simulation endeavors, I contemplate the varied experiences and solid competencies I’ve gained throughout my tenure as a Manufacturing Implementation Specialist. However, I steadfastly uphold the spirit of perpetual learning. I’m motivated by an inherent inquisitiveness and the pursuit of constant refinement, in both professional and personal spheres. With this intention, I am enthusiastically seeking to fortify my proficiency through advanced studies. I view this as a chance to probe deeper into the nuances of manufacturing process optimization, scrutinize upcoming methodologies, and test my abilities within a stringent scholastic setting. My dedication to broadening my knowledge and skills will not only amplify my aptitude but also contribute innovative solutions and value to impending engineering quandaries.
Clients: Work Portfolio, volunteer work and freelancing projects.
Date : 2019 to Present
In the domain of mechanical design and product lifecycle management, I continually strive for innovation, underpinned by comprehensive research into scientific literature and technology advancements. My work is committed to delivering precise, user-focused, and risk-free products that cater to evolving modern needs, from initial concept to commissioning.
In creating these solutions, I combine theoretical expectations with practical feasibility. My design methodology integrates procedures like Product Requirement Document (PRD), Failure Mode Effects Analysis (FMEA), and Creepage and Clearance studies for electronics products. This approach guarantees robustness, operational safety, and adherence to international standards. I also prioritize user requirements, safety regulations, and efficiency metrics, leading to high-quality designs.
My contributions to the field are fueled by experimental research methods such as Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) simulations. I utilize these techniques to assess and refine design concepts under varied conditions, yielding critical quantitative data. Complementing this, qualitative research methods provide an understanding of real-world applications. I ensure the products I design are technically robust and user-oriented through a series of case studies and user interviews.
In line with the rapidly evolving field, I keep abreast of the latest advancements through exhaustive literature reviews and academic papers. The gleaned insights are incorporated into my presentations, ensuring decision-makers are informed about emerging technologies and strategies.
Beyond core design, I play a crucial role in enhancing operations and implementing process improvements. I’ve developed comprehensive work instructions integrated into the Manufacturing Execution System (MES) for smoother workflow and seamless transition from design to production. I’ve modernized drawing templates to reflect recent technological strides, contributing to increased efficiency, reduced errors, and improved team collaboration.
In an agile project environment, I’ve contributed to policy development for handling Engineering Change Orders (ECO), ensuring rapid, efficient adjustments with minimal project disruption.
I’ve also produced detailed instructions for Installation, Operation, and Maintenance (IOM) activities and comprehensive design documents, facilitating correct practices and enabling smooth project handovers. Furthermore, I prioritize generating lab test reports in accordance with rigorous standards, providing a valuable resource for our team and stakeholders.
My ultimate objective, whether working on standalone components or complex systems, is to deliver top-tier, cost-effective, and sustainable solutions in alignment with current trends, thereby meeting the requirements of the modern world.
Clients: Work Portfolio, volunteer work and freelancing projects.
Date : 2019 to Present
In an age of digital revolution, I’ve extended my interest towards the intersection of Industry 4.0 and Supply Chain Management, which is transforming traditional operations. My ongoing MITx Micromasters in Supply Chain Management is focused on leveraging advanced technologies like AI, IoT, and Big Data to optimize, predict, and simulate logistics and manufacturing processes. This knowledge directly feeds into my work, enhancing operational efficiency and end-to-end visibility in the production line.
Incorporating immersive tech, we leveraged VR and AR headsets during prototype assembly, thus revolutionizing traditional processes. Our comprehensive IOM instructions and digital documents ensure smooth assembly.
Moreover, my research interest lies in the potential of these digital technologies to revolutionize supply chains and create smart factories. With keen attention on AI-powered automation, predictive analytics, and real-time monitoring systems, I am eager to explore how these innovations can bring about resilience, responsiveness, and sustainability in supply chains.
In pursuit of digital revolution, I’ve co-authored and submitted a review paper in “A Correlation Among Industry 4.0, Additive Manufacturing, and Topology Optimization,” encapsulating the latest industry 4.0 trends.
Looking ahead, I am excited about the opportunity to further my studies and research in this groundbreaking field. I intend to delve deeper into the intricate world of AI-powered Industry 4.0 and supply chains, aspiring to contribute significantly to the discourse and practice of future manufacturing and logistics.
Clients: Volunteer work and freelancing projects.
Date : 2021 to Present
From a very young age, my fascination with technology was irrevocably ignited by the magic of the Star Wars universe. It was there, captivated by the antics of the lively and unique characters such as R2-D2 and C-3PO, that I first found myself enthralled by the concept of robotics. These complex, sentient, and sometimes comical characters inspired my lifelong interest in how robotics and AI could not only interact with humans but also contribute significantly to the betterment of our lives.
Embracing this fascination, I found myself gravitating towards the intersection of robotics, prosthetics, and Industry 5.0. Driven by a mission to create a world where the line between humans and machines is increasingly blurred, I am currently fascinated by the process of designing and developing advanced robotic prosthetics.
My design process marries function with aesthetics, leveraging cutting-edge technology to create prosthetics that are not just tools, but extensions of the human body. From AI-powered mobility solutions to IoT-enabled sensory integration, the prosthetics I design are rooted in enhancing human capabilities and improving quality of life.
Moreover, my research interest lies in harnessing these technological innovations to push the boundaries of what’s possible in robotics and prosthetics. With a keen focus on AI-powered automation, real-time adaptive systems, and biomechanical optimization, I am eager to explore how these technologies can transform healthcare and human capabilities.
Having completed a comprehensive Robotics Specialization at the University of Pennsylvania, I have acquired a well-rounded understanding of this dynamic field. The courses encompassed in this specialization – Aerial Robotics, Computational Motion Planning, Mobility, Perception, Estimation and Learning, and a Capstone Project – have equipped me with a robust knowledge base and a diverse set of skills.
In Aerial Robotics, I learned the dynamics of flight and the design principles of aerial robots. Computational Motion Planning introduced me to the exciting world of robot path planning and navigation. The Mobility course enhanced my understanding of how robots move and interact with their environment. In Perception, I developed skills in machine vision and sensor integration, vital for a robot’s interaction with its surroundings. Estimation and Learning course strengthened my grasp on AI and machine learning applied to robotics.
For my Capstone project, I applied these learnings to design a robo-car with IoT-enabled sensory input. This project required me to draw upon my understanding of robotics.
Looking ahead, I am thrilled to further delve into the world of robotics and prosthetics, aspiring to contribute significantly to the discourse and advancements in this fascinating field. Spurred by the childhood memories of watching droids saving the galaxy, I remain committed to leveraging technology to create a brighter, more inclusive future. Here’s to creating the ‘droids’ of our time!
Clients: Work Portfolio, volunteer work and freelancing projects.
Date : 2019 to Present
Within the fast-paced and creative realm of rapid prototyping and mechanical design, I’ve gained comprehensive knowledge and experience over the years, especially through my current role at a cutting-edge rapid prototyping facility. My work here provides a playground where I can apply my skills to transform virtual ideas into tangible objects using state-of-the-art machines, such as 3D printers and CNC routers.
My engineering expertise and my knowledge of rapid prototyping have come together to drive my interest in designing efficient, innovative mechanical systems. Starting from concept development through to prototyping and rigorous testing, my comprehensive and iterative design process has allowed me to create mechanical designs that are not just functional but also innovative and robust.
One key area where I’ve had the chance to implement this process is during the creation of virtual prototypes. By utilizing VR and AR technologies, we were able to push the boundaries of traditional prototype assembly, bringing new perspectives to the design process and streamlining workflows. The resulting prototypes were not only easier to assemble but also gave stakeholders a better understanding of the end product before it was fully realized.
However, my curiosity doesn’t end with creating these tangible designs. I’m also deeply interested in how emerging technologies can revolutionize the field of mechanical design engineering. With a focus on AI-powered automation, predictive analytics, and real-time monitoring systems, I’m eager to explore how these tools can bring about higher efficiency, precision, and adaptability in mechanical design and manufacturing.
Moving forward, I am enthusiastic about deepening my understanding of this exciting blend of mechanical design and rapid prototyping. My goal is to significantly contribute to the evolving discourse and practice within this space, aiming to push the boundaries of what is possible and to create mechanical designs that are efficient, innovative, and responsive to the ever-evolving technological landscape.
Clients: Work Portfolio, volunteer work and freelancing projects.
Date : 2022 to Present
As we stand at the cusp of the Fourth Industrial Revolution, my fascination lies at the intersection of cybersecurity, Industry 4.0, and the transformation of traditional infrastructures into intelligent systems. Through the MITx course “11.S198x: Cybersecurity for Critical Urban Infrastructure”, I have honed my expertise in safeguarding complex systems against cyber threats, while ensuring the efficient and secure operation of our digital future.
Delving into a world augmented by IoT, Robotics, and AI, I am continually developing my skills in securing and optimizing these technologies. My proficiency is highlighted by the completion of a comprehensive training that involved building robust cybersecurity measures for a wide range of devices, including IoT devices, robotic systems, CNC machines, and 3D printers. This expertise directly complements my work, enhancing system security and resilience against cyber threats, while fostering innovation and operational efficiency.
In addition, my research interest lies in exploring the revolutionary potential of these digital technologies, particularly their application within the realm of smart factories and urban infrastructure. With a keen focus on AI-empowered automation, predictive analytics, real-time monitoring systems, and the cybersecurity aspects enveloping these elements, I am eager to delve deeper into the synergistic effects of these innovations, and their role in creating resilient, responsive, and sustainable urban systems.
As part of my commitment to advancing in this field, I co-authored and submitted a review paper titled, “A Correlation Among Industry 4.0, Additive Manufacturing, and Topology Optimization”. This work encapsulates the latest trends in Industry 4.0, including the implications of digital manufacturing technologies, and the critical need for robust cybersecurity measures in this emerging landscape.
As I continue, I am keen to deepen my research and studies in this exciting and critical field. I am passionate about exploring the intricate interplay of AI, IoT, robotics, and cybersecurity within the context of Industry 4.0. My ultimate aspiration is to make significant contributions to the discourse and practice of cybersecurity, particularly in the protection of our digital future against evolving cyber threats.
The MicroMaster program covers supply chain modeling methodologies, network design, system interactions, technology applications from basics to advanced software systems, and holistic end-to-end supply chain management.
• Skilled in robot flight, movement, and environmental perception. • Completed a capstone project programming varied robot movements. • Knowledgeable about future potential capabilities in robotics.
• Final Year Project: Design of Waste-to-Energy Power Plant • Top 5% of the class - CGPA: 3.78/4.0 • Dean's List 1st, 2nd and 3rd year • Elected to President for NUST PNEC Media Club in 2018
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