Muhammad Salman Sarfraz

Researcher

Department of Mechanical Engineering, KAIST, South Korea (2019-Present)

Development of high heat dissipating and low viscosity underfill materials for flip chip technology using 3D nanostructured particles
Developing numerical-based solutions for curing process optimization of fiber-reinforced composites
Developed a novel soft magnetic composite (SMC) for electromagnetic applications
Developed an ultra-thin, lightweight BLDC motor for a wearable robotic suit featuring a novel SMC core
A brief review of recent developments in the manufacturing technologies of composite components and their cost-effectiveness in the automotive industry
Developed a novel sandwich composite spring and its applications

Sensor-integrated foam core sandwich spring capable of measuring bending deformation
Composite spring capable of energy harvesting based on triboelectricity

Flipchip underfill materials for the National Semiconductor Laboratory

Development of high heat dissipating and low viscosity underfill materials using 3D nanostructured particles
Developing novel solutions for underfill materials, competing with advanced industrial underfills

Development of numerical-based solutions for composite materials, structures, and manufacturing techniques

Developing governing equations and new numerical solutions for multiscale optimization of composites
Working on the development of an optimal cure profile cycle for thick and cross-directional carbon fiber-reinforced plastics for manufacturing hydrogen storage cylinders by using filament winding methods

Tools: ABAQUS, MATLAB, COMSOL 6.0, COMPro, Raven

Skills: Machine Learning, Artificial Intelligence, Programming

Ultra-Thin BLDC Motor using Soft magnetic composites

Design and Analysis (Electromagnetic, Thermal, and FEA) of BLDC motor
Features a novel SMC core tested for magnetic and physical properties

Tools: SolidWorks, ANSYS (electromagnetism, MotorCAD), Scanning Electron Microscopy (SEM), Optical Microscope (OM), Vibrating Sample Magnetometer (VSM), Thermogravimetric Analysis (TGA), Centrifugal Mixer, CNC, and Hot-Press

Brief Study of Advanced Composite Manufacturing Technologies

Composite manufacturing technologies and their feasibility for mass production of automotive components
Cost-effectiveness of advanced manufacturing technologies
Composite joining technologies and their feasibility

Sensor-integrated Foam Core Sandwich Composite Spring for lower-limb exoskeleton robots

Designing a composite spring for fast running wearable robotic suit
FEA Analysis for mechanical performance
Fabrication by using an autoclave
Testing of bending deformation measurements

Tools: ABAQUS/CAE (FEA Analysis), Artificial Neural Network (ANN)

Composite Material Spring Capable of Self-Energy Harvesting Based on Triboelectricity

Composite spring capable of energy harvesting
Fabrication by using an autoclave
Testing of energy harvesting and mechanical performance

Tools: ABAQUS/CAE (FEA Analysis), Artificial Neural Network (ANN)

Undergraduate Research Fellow (2017-2018)

Department of Mechanical Engineering, UET Lahore, Pakistan

Development Renewable Energy Assessment Report (Wind Energy) for Offshore Areas (3 Locations) in Pakistan, a Comparative Analysis of Measured Wind Data with Different Satellite Datasets, and Modelling of Analysis Tool for Wind Assessment
Development of Preventive Maintenance Planning Model for CNC Milling Machines

Professional Work, Worked as Intern

1. Maintenance Department, HONDA, Pakistan (2017)

Worked on CNCs (Operation and Maintenance)
Worked on Die Casting (Operation)

2. Corrugation Department, BullehShah Packages, Kasur, Pakistan (2016)

Worked on Automation of Production Units to Utilize Less Deployment
Worked on Efficient Space Utilization
Worked on Corrugation Machine (Operation & Maintenance)

Term Projects and Assignments

Double Cantilever Beam (DCB) Fabrication and Adhesion Testing of Cu/ and Cr/ Thin Films (Joining Engineering Project)
Designing and Manufacturing of Actuator Assembly (Machine Design Project)
Modeling and Analysis of Stress Development in a Crankshaft (Machine Design Project)
Design of Pressure Vessel ASME VIII Spherical (Mechanics of Materials Project)
Numerical Solution of Incompressible Laminar Flow in A 2D Channel (Fluid Mechanics Project)
Preventive Maintenance Planning Model of CNC Milling Machines (Industrial Engineering & Production Management Project)
Proposed New Refrigerant Blend by Decreasing GWP and Increasing COP in Comparison with R-134a (Refrigeration and Air-Conditioning Project)
Designing and Manufacturing of Air Driven Engine (ASME UET LAHORE)

Voluntary Works, Worked on Following Positions

Representative of KAIST International Kitchen (2020-2021)
Member of Pakistan Students Association (PSA) at KAIST (2019-2021)
President of Mayo Professionals Society at UET Lahore (2016-2018)
Session Representative of Kasur Student Society of UET Lahore (2014-2018)
Member of Volunteer Club Mechanical Engineering Department at UET Lahore (2018)