projects

Research and engineering projects in computational mechanics, digital twin development, and AI/ML-enabled simulation tools.

All work listed below was conducted under industry research programs. Implementations remain proprietary; descriptions reflect generalized research contributions.

2023 – Present

  • Digital Twin Framework for Advanced Manufacturing

    Developing end-to-end digital twin infrastructure integrating physics-based process simulation, real-time sensor data, and validation workflows for advanced manufacturing programs.

    • Architecting sequential thermal–mechanical coupling framework with Python-based automation.
    • Validating residual stress and distortion predictions against in-situ thermocouple measurements.
    • Delivering parameterized HPC job-management pipeline for cluster-scale execution.
    • Integrating boundary-condition identification and model calibration workflows for virtual process qualification.
  • AI/ML-Enabled Materials & Process Prediction Platform

    Building GUI-based software tools combining transformer-based language models with physics-based simulation for materials property prediction, inverse design, and LLM-assisted FEA automation.

    • Architecting ML-powered software combining transformer language models with Abaqus-based simulation.
    • Benchmarking transformer architectures against high-fidelity RVE micromechanics outputs.
    • Developing GUI front-end exposing FEA workflows to non-CAE users.
    • Implementing inverse-design workflows for composite property targets.

2022 – Present

  • Thermomechanical Process Simulation — Solid-State Manufacturing

    High-fidelity coupled thermal–mechanical FEA of solid-state additive manufacturing processes — covering heat generation, deposition sequencing, residual stress, and experimental validation.

    • Developed spatially-distributed heat generation model as a Fortran user subroutine.
    • Built path-synchronized element activation for multi-layer deposition sequencing.
    • Validated residual stress prediction workflow against thermocouple measurements for multi-layer AFSD.
    • Automated end-to-end simulation pipeline from CAD geometry through HPC execution and post-processing.

2021 – Present

  • Multi-Physics Modeling of Quenching Processes — Aluminum & Airframe Components

    Developing multi-physics digital twin and planning tools for industrial quenching — coupling thermal, metallurgical, and mechanical phenomena to predict distortion, residual stress, and microstructure evolution in aluminum and airframe structural components.

    • Coupled thermal–metallurgical–mechanical FEA for aluminum and metallic structural components.
    • Optimization framework for tailoring quenching processes of representative airframe components.
    • Digital twin architecture for large-scale metallic-structure quenching.
    • Recognized with Vertical Flight Society Best Paper Awards in 2024 and 2025.

2020 – 2022

  • Defect-Aware Composite Structural Analysis — Aerospace Structures

    Delivered global-to-local aircraft wing simulation frameworks incorporating manufacturing distortion, XFEM-based fatigue crack growth, CDM progressive damage, and CFD-driven thermal loading.

    • Built global-to-local sub-modeling framework for aircraft wing structural assessment.
    • Implemented XFEM-based fatigue crack growth with defect-informed initiation.
    • Integrated CDM progressive damage in composite laminates.
    • Coupled CFD-driven thermal loading with structural model; mapped manufacturing distortion onto as-built geometry.

2019 – Present

  • Multiscale RVE Micromechanics & Digital Material Generation

    Developed digital material generation toolkits for composite laminates — predicting ply-level elastic, strength, and thermal properties using RVE-based micromechanics, with explicit treatment of manufacturing defects.

    • Developed digital material generation toolkit predicting ply-level elastic, strength, and thermal properties.
    • Implemented explicit RVE modeling of voids, fiber waviness, and ply misalignment.
    • Linked micro-scale defect distributions to macro-scale structural performance.
    • Integrated toolkit into broader simulation and digital twin pipelines.

2014 – 2017

  • Composite Fabrication & Experimental Characterization

    Designed and executed experimental programs covering composite panel fabrication, mechanical and thermal testing, and microscopy-based defect characterization.

    • Fabricated composite panels (layup, debulking, autoclave cure) under ASTM-compliant procedures.
    • Performed mechanical testing: Mode I/II fracture, fatigue, short-beam shear, stress relaxation.
    • Conducted thermal characterization (DSC, CTE, thermomechanical response).
    • Microscopy-based defect characterization feeding directly into FE model validation.
  • Nonlinear FEA & Multiscale Modeling — Honeycomb Core Structures

    Investigated forming and creep behavior of honeycomb sandwich structures using advanced nonlinear FEA and micro–macro multiscale modeling.

    • Nonlinear FEA of honeycomb forming under spherical, cylindrical, and multi-radius bending (MSC Marc).
    • Micro–macro multiscale modeling of woven composite honeycomb cores.
    • Custom FORTRAN subroutines for anisotropic hyperelastic creep behavior.
    • Foundation methodology for later defect-aware composite analysis and digital twin work.