SHAHADAT
HUSSAIN.
Ten years turning powder, polymer, and molten metal into engineered structures — laser powder bed fusion, multi-material 3D printing, and shape memory alloys, characterized and tested to spec. Based in Abu Dhabi.
Bench-to-spec materials engineering
I'm a Research Associate in the Division of Engineering at NYU Abu Dhabi, holding a PhD in Materials Science & Technology (AcSIR / CSIR-AMPRI) and a BEng in Mechanical Engineering. Over a decade across institutions in India and the UAE, I've worked the full pipeline — computational design, additive manufacturing, and experimental characterization — on architected materials that have to perform, not just publish.
Before NYU Abu Dhabi, I held a postdoctoral fellowship at Khalifa University, fatigue- and tensile-testing NiTi shape memory wires and mapping how laser process parameters drive microstructure in 3D-printed NiTi lattices. That process-parameter-to-property discipline is the same one industry needs on a factory floor.
My current work spans Fused Filament Fabrication, Stereolithography, and hybrid casting routes for TPMS gyroid and primitive lattices — including Interpenetrating Phase Composites and a green-steel additive manufacturing track using stainless-steel-reinforced filaments for structural parts.
Process-to-property discipline
Every material choice traced back through process parameters to mechanical outcome — the exact mindset a production line needs when a spec is on the line.
Multi-material, multi-process fluency
Comfortable moving between polymer FFF, resin SLA, metal LPBF, and casting on the same project — not locked into a single machine or material family.
Test-bench rigor
Compression, four-point bending, tensile, and fatigue testing run to characterize real failure modes, not just pass a checklist.
Safety-trained, lab-floor ready
Certified in chemical, fire, electrical, and cryogenic lab safety, including hydrofluoric acid handling — comfortable on a regulated production or test floor from day one.
Core capabilities
Additive Manufacturing
- FFF — carbon/glass-fiber reinforced polymers
- SLM / LPBF — NiTi & metal TPMS lattices
- SLA — wax-resin casting patterns
- PolyJet, hybrid casting routes
Materials Systems
- NiTi shape memory alloys
- TPMS gyroid & primitive lattices
- Interpenetrating phase composites
- Stainless-steel green AM filaments
Analysis & Imaging
- SEM / FIB, EDS, EBSD, AFM
- XRD phase analysis
- DSC thermal / transformation analysis
- Optical microscopy & metallography
Testing + Data Science
- Instron / MTS tensile, fatigue, compression
- Four-point bending, hardness testing
- Python, MATLAB, scikit-learn, SQL
- Materials informatics & ML modeling
Work experience
PRESENT
- Developed FFF processes for carbon- and glass-fiber reinforced composites (PPA, PLA, ABS, Nylon) on a Raise3D Pro3 Plus HS.
- Built hybrid metal-lattice routes — SLA wax-resin patterns, gypsum investment casting, aluminum alloy pour.
- Produced green-steel TPMS structures via stainless-steel-polymer filament printing, debinding, and sintering.
- Ran compression and four-point bending programs on TPMS and IPC parts to quantify stiffness, energy absorption, and failure mode.
JUN 2024
- Characterized additively manufactured NiTi TPMS lattices (Schwarz primitive, Schoen gyroid) fabricated via LPBF.
- Ran tensile and fatigue testing on NiTi wires across diameters, compositions, and surface treatments on an Instron 8872.
- Applied SEM, XRD, EDS, EBSD, and AFM to correlate process parameters with microstructure and phase behavior.
AUG 2014
- Synthesized Cu-based shape memory alloys via vacuum induction melting; ran heat treatment and hot rolling.
- Delivered 5 SCI-journal publications from a Government of India-sponsored smart-materials program.
JUL 2011
- Two-week industrial training across Coke Ovens, Blast Furnace, Steel Melting Shop, Continuous Casting, and Hot/Cold Rolling Mills — first hands-on exposure to heavy steel manufacturing.
Machines I run
3D PRINTING
MECHANICAL TESTING
DESIGN, SIM & DATA
Featured research & builds
Interpenetrating Phase Composites
3D-printed TPMS gyroid and primitive lattices impregnated with resin to produce multiphase architected materials engineered for structural strength and vibration damping.
Green Steel AM
Stainless-steel-reinforced polymer filaments printed, debound, and sintered into structural TPMS forms — a sustainable fabrication pathway for heavy components.
NiTi TPMS via LPBF
Mapped how laser scanning strategy and relative density drive balling, cracking, and non-uniform solidification in laser powder bed fused NiTi lattices.
Cast Metal TPMS Beams
SLA-printed polymer TPMS patterns used as sacrificial templates for aluminum alloy casting — combining additive geometric freedom with cast-metal mechanics.
Built for the factory floor, not just the fume hood
My research runs on the same coordinates as the UAE's industrial roadmap — advanced manufacturing, local value creation, and Industry 4.0 readiness. Every project is built the same way: read the spec, choose the right process and material, run the test program, and explain the failure mode in plain terms.
That process discipline is what turns a lab result into a part that ships.
Operation 300bn
Work aligned with the UAE's national push to grow industrial GDP and localize advanced manufacturing capability.
Make it in the Emirates
Hands-on additive manufacturing and materials work that supports building production capability inside the UAE.
National In-Country Value (ICV)
Research directed at local value creation — from green-steel AM to homegrown materials testing infrastructure.
Education & certifications
Doctoral research on grain refiners, alloying additions, and processing parameters in Cu-Al-Ni shape memory alloys for high-temperature applications.
Major project on biomass gasification for internal combustion engines; industrial internship at Bokaro Steel Plant.
Let's build something that ships.
Open to research collaboration, industrial consultancy, and new opportunities in advanced manufacturing and materials engineering.
contact@shahadathussain.com