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Mudassar Khalil

Our PhD Students

Loughborough University

Mudassar is a PhD student at Loughborough University. He joined in July 2022 and his work is focused on design, manufacture and validation of porous materials and multifunctional structures. He holds a Bachelor’s degree in Mechanical Engineering from UET Lahore, Pakistan and Master’s degree in Polymer Technology from Aalen University, Germany. In his master’s thesis, he worked on developing the part design rules for pin headers to control the warpage problem by simulation and practical application.

After his master’s degree, he worked for 12 years in academia. He taught design and manufacturing courses and supervised undergraduate student projects. He worked on the preliminary design of an automatic pipe cleaning system in collaboration with the college research center and the client industry. In addition, he was involved in curriculum development, ETAC/ABET accreditation, E-Learning and E-Testing activities during his academic career. His area of technical expertise is CAD/CAM/CAE, DfAM, FDM technology and tool manufacturing.”

RIED Specific Links & Papers

  • Simulation and physical validation of triply periodic minimal surfaces-based scaffolds for biomedical applications (June 2024)

    This paper was presented at the June 2024 NAFEMs Conference. NAFEMS is the International Association for the Engineering Modelling, Analysis and Simulation Community.

    Metallic scaffolds are used as implants to help heal bones. Sheet-based Triply
    Periodic Minimal Surfaces (TPMS) are of interest due to their high surface-to-volume ratio (S/V), customisable stiffness, and can be realised using Additive Manufacturing (AM). Other studies investigate porosity and pore size of scaffolds but they frequently overlook S/V, which is critical for cellular response. Additionally, the limitation of AM (esp. Selective Laser Melting (SLM)) causes discrepancies between intended and actual physical and mechanical properties of those structures, and this also needs to be addressed. This work investigates three types of TPMS scaffolds made in pure Titanium, with an emphasis on design vs manufactured differences and the significance of S/V. As-designed scaffolds reported 70-75% porosity and 25-35 cm-1 S/V, and stiffness was measured using finite element analysis (FEA) at 6.7-9.3 GPa. The manufactured scaffolds had 59-70% porosity and 33-42 cm-1 S/V. Laboratory compression testing revealed an effective Young’s modulus of 5-9 GPa, comparable to bone. Image-based simulation method was also employed on the built samples which reported the stiffness range of 8.3-16.6 GPa, overestimating it by 57%. It is hypothesised that these discrepancies stem from the secondary roughness deposited on the scaffold walls during SLM, causing reduction in porosity yet not contributing to structure’s strength. The cyber physical validation methods presented are a good way to quantify these
    discrepancies, allowing feedback to the design stages for more predictable as manufactured structures.

    https://www.nafems.org/publications/resource_center/uk24_ext_abs_18

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