About

Elevate Your Product Design with Professional Guidance!

Are you ready to bring your product ideas to life?

Whether you're launching a new design, troubleshooting a past failure, or managing a product’s lifecycle, I’m here to help you succeed.

What I Offer:
I specialize in turning concepts into reality using advanced CAE tools tailored to your project needs.

My expertise spans:
• Concept Design & Material Selection:
Crafting the foundation of your product with thoughtful choices grounded in engineering methodology. Selecting the right materials is crucial for performance, durability, and cost-effectiveness. I guide you through the entire selection process, ensuring your materials align with your design goals and operational requirements. I will create a virtual model of the concept design with the latest 3D parametric modeling techniques and tools.

• Detailed Engineering Design:
Utilizing FEA (Finite Element Analysis), CFD (Computational Fluid Dynamics), and FSI (Fluid-Structure Interaction) for thorough analysis and optimization. My simulations provide insights into potential performance issues, allowing us to make informed design decisions early in the process.

• 3D Modeling & Prototyping:
Delivering precise engineering drawings or 3D detailed CAD models for rapid prototyping, machining, or fabrication. I create detailed 3D models that accurately represent your product, facilitating effective communication with manufacturers and stakeholders. Incorporating relevant manufacturing tolerances and maximizing product service life.

With over 22 years of hands-on experience in FEA and CAD, I’ve collaborated with renowned international companies and diverse industries to drive projects from initial concept to final fabrication. My commitment to quality and innovation has helped numerous clients transform their visions into market-ready products.

Industries I've Worked In:
• Electric Vehicles
• Light/Heavy Vehicle Stability and Crash-worthiness
• Gas Turbine Engines
• Cryogenics
• Unmanned Aerial Vehicles (UAVs)
• Pneumatic Launching Systems
• Biomedical Prosthesis

My Experience Includes Work With:
• American Engineering Services:
(Expertise in reverse osmosis and water treatment solutions)
• Dassault Systèmes of America:
(Specializing in CATIA and ENOVIA)
• CESAT:
(Advanced simulation using ANSYS, LS-DYNA, FLUENT, & CFX)
• Engineering Universities:
(Educating the next generation with SolidWorks, CATIA, and ANSYS training. I have taught Solid Mechanics, Mechanical Vibrations, FEA, & CAD as an assistant professor in the mechanical engineering programs.)

Notable Projects:
• Composite UAV Design & Optimization
• Fatigue Analysis of Turbine Blades
• Dynamic Analysis of Gas Turbine Engines
• Design & Validation of Shock Isolation Systems
• Random Vibration Analysis for Aerospace Components
• Cavitation Studies of Pumps
• Innovative Designs for Medical Devices & Energy Solutions

Whether you’re in need of consultancy for commercial ships, oil rigs, or power plants, I provide tailored solutions to ensure your project not only meets but exceeds expectations.

Let’s Collaborate!

My approach combines technical expertise with a passion for innovation, ensuring that every project I undertake is met with the highest standards of quality and creativity. I thrive on challenges and believe that collaboration is key to achieving outstanding results.

If you’re looking for a partner who can bring expertise and innovation to your product design journey, don’t hesitate to reach out. Together, we can turn your vision into reality! I am excited to explore how we can work together to elevate your projects and drive success in your endeavors.

Let’s start a conversation about your needs and how I can help you achieve your goals.

Experience

  • Founder/CEO CAE Consults · Self-employed Jul 2017 – Present 7 yrs 5 mos Karachi, Sindh, Pakistan Develop and deploy training in CAD, FEA, and PLM (CATIA/ENOVIA, SolidWorks, Autodesk, ANSYS / LS-DYNA)

    Explicit Dynamic Analysis of a UAV shuttle assembly impacting flexible barrier at high velocity

    Blade Flutter and Forced Response Analysis (Fluid Structure Interaction in Turbomachinery Training Module)

    Chassis Design and Vehicle Crash Worthiness of Electric Vehicle – Initial Proposal Private Contractor (Structural Design, Optimization, and Crash Analysis of Chassis)

    Parametric Modeling of Smart Crib Motorized Rocking Assembly. – Private German Contractor

    Optimization and Analysis of UAV – ZGI Robotics
    (Composite Structural simulation and optimization of HSTD UAV using parametric study)

    Investigate and predict fatigue failure in structural components – Pakistan International Airlines (Turbine/Compressor blades)

    Investigated pump cavitation in centrifugal/axial pumps – Private Contractor (Developed training modules for its simulation and avoidance)

    Predict dynamic response characteristics of heavy truck trailers – Metal Engineering Work (Pvt) Ltd. (Rollover, acceleration threshold and lateral stability.)

    Training development in CFD – The CAE Blog

    Provide technical support in structural mechanics and dynamics

    Establish and maintain consultation service with reputable clientele
  • Chief Design Engineer, Chief Operating Officer, Consultant SoluNox · Full-time Dec 2020 – Sep 2024 3 yrs 9 mos Karachi, Sindh, Pakistan I am responsible for the design, engineering analysis and on-site management in the complete SoluNox product range which includes UAVs, HSTD Pneumatic Catapult Launcher, Micro Gas Turbine Engines, Vehicle Engineering (Heavy/Light vehicle dynamics and roll-over, Weight optimization, Crash worthiness through simulation and analysis, electric vehicles), renewable energy (hybrid wind turbine), cryogenic containment technology, and project Zuhra (A.I. driven rapid prototyping of hard/soft tissue prosthesis and implants. This technology is also augmented into virtual-reality diagnosis and a training tool for doctors and surgeons).

    Project Director:
    1. UAV Launcher
    Manjaneeq MR1-1
    (High Speed Heavy Launching Platform)

    2. Micro Gas Turbine Engines
    (SLX Series)

    3. Hybrid Wind Turbine

    4. Electric Vehicles
    A. Three Wheeler Concept Design
    - Long and Short Wheel Base Passenger Carriers
    - Open Cargo Carrier
    - Closed Cargo Carrier

    Development and Implementation:
    1. Engineering Design Center for Simulations.
    2.

    Establish and Liaison relevant industries for technical and strategic partnerships.
    3. Provide technical support and consultancy in engineering simulations and on site management for structural mechanics and dynamics in complete product range.
  • Assistant Manager - Structural Dyanmicist CESAT · Full-time May 2007 – May 2024 17 yrs Islamabad, Islamabad Capital Territory, Pakistan Structural Dynamics Team

    Responsible for:

    Modal Analysis, Harmonic Analysis, Transient Dynamic Analysis, Random Vibration Analysis, Rotor Dynamics, & APDL.
  • Application Engineer Dassault Systemes of America · Full-time Feb 2005 – Jun 2006 1 yrs 4 mos Los Angeles, CA, United States (CATIA)

    Responsible for Mechanical Design, Plant Layout, Piping, Tubing, Equipment Arrangement, & HVAC.

    Trace & replay product functionality to increase code coverage in major frameworks.

    Maintain & Update sample catalogs in major frameworks in file base & ENOVIA.

    Stress test functionality in 3D routable applications & design test scenarios to quantify CPU times.

    Perform functional/integration testing on new & existing functionality in 3D outfitting products .

    Validated customer models in analyzing, cleaning & resolving data through 3d routable applications & mechanical design. Customers included Frigotechnica (industrial refrigeration plants), PEMEX (oil rigs), & USC (ship builders).

    Created a best practice for drawing production with multiple work packages in ENOVIA for ship building clientele. Majority of work was in migration and with ENOVIA Reconciliator.

    Created 3D equipment assembly catalogs for HVAC Piping, & Tubing workbenches. Modeled assemblies in Mechanical Design. These sample assemblies were included in the next software release of CATIA.

    Quantified memory enhancement in drawing production for large assemblies with various GVS files.

    Instructor Lead Training in Plant Layout, Equipment, HVAC Piping, Tubing & Mechanical Design workbenches.

    Extensive experience with 3D detailed design products.

Education

  • University of Southern California Meng in Computer Aided Engineering, Computational Mechanics, 3.85 2003 – 2005 Activities and Societies: null Major: Structural Mechanics & Dynamics, FEA.
    Minor: Computer Programming & Computer Graphics
  • Ghulam Ishaq Khan Institute Bachelors of Science in Mechanical Engineering, Mechanical Engineering 1998 – 2002