Mahyar K, PhD

During his PhD and professional career, Mahyar worked on advanced projects in the medical, automotive and, aerospace industries. He worked on a Multi-Disciplinary Design-Optimisation project for Ford (2022) and Boeing Aerospace-Company (2021) on the simulation of 3D printing of polymeric materials and developed a numerical tool to improve the 3D printing technology for the production of aircraft and automotive internal parts with superior properties. Another part of his research was dedicated to the production of Airbus air-manifold by two different methods including machining and 3D printing. The project was implemented in Aeronamic-Company (Netherlands in 2018) and Mahyar developed a model to measure and optimise the production costs and time to improve the efficiency of 3D printing technology.

 

He has done extensive work on cost estimation for additive manufacturing processes for pre-processing, process and post-processing. He also has done a project in the medical aspect of additively manufactured parts. There Mahyar developed the design and post-process for a 3D-Printed human-customised hip joint for a patient who had an accident (2017).

 

He further explored the science that is behind printing technology which has been reflected in his publication track record as well as industrial projects.

 

He has been the recipient of prestigious academic research awards comprising

• the Top 10 best PhD thesis for a project in metal printing, Deakin University (2017)

• an Endeavour Fellowship Award (2018) for a project in postprocessing of additive manufacturing,

• Deakin Vice-Chancellor’s Fellowship Award (2019) for the project in metal printing,

• Fulbright Fellowship Award (2021) for a project in polymeric additive manufacturing,

• Bestseller award for global leading textbook in Additive Manufacturing (2021),

• Top 50 bestselling textbook in Springer Publication, (2018-2021) for “Additive Manufacturing Technologies”,

• Member of Parliament Award for Research Impact (2022), and RMIT Vice-Chancellor's Award for Research Excellence ECR (2022) for industrial additive manufacturing projects.

 

Mahyar is also the Associate Editor-in-Chief of the Rapid Prototyping Journal, which is the first established journal in 3D printing (1994).

 

In his advisory sessions, he can offer any training on additive manufacturing for different processes including:

• Powder Bed Fusion also known as Selective Laser Melting and Selective Laser Sintering,

• Vat Photopolymerization also known as Stereolithography,

• Material Extrusion also known as Fused Filament Fabrication, Fused Deposition Modelling,

• Sheet Lamination,

• Directed Energy Deposition,

• Binder Jetting and 7-Material Jetting.

 

Furthermore, he can advise for 3D printing process selection based on the required marketing application. He can advise on design for additive manufacturing for topology optimization and part consolidation.

 

As for many 3D printing processes the mechanical properties, surface quality and dimensional accuracy of the parts cannot meet industrial application standards; different post-processing strategies are required to improve the part quality. Mahyar can offer a proper roadmap for the post-processing of 3D-printed parts based on industrial applications for qualification.

 

As one of the main considerations for companies who are looking to turn to additive manufacturing is cost estimation; based on his previous experience in providing cost models for 3D-Printed industrial parts, Mahyar can provide the best and most comprehensive cost model comprising pre-process, process and post-processing.

 

Good materials are crucial for effective 3D-Printing, and different processes require these materials to be prepared in different ways. Mahyar can offer a proper material selection based on the industrial application and required mechanical properties of the parts. He can develop a mathematical and numerical model for any 3D-Printing process to predict the results that the client is looking for. In addition, he can benchmark various simulations on micro and macro scales for process optimization to predict the behaviour of the printed parts before starting the printing job. A predictor model and simulation save a huge amount of time and cost.

 

With his in-depth knowledge, Mahyar can offer, process selection, material selection, problem-solving for part defects, cost estimation, modelling and simulation. He can do any training for different processes of 3D-Printing such as

• Powder Bed Fusion also known as Selective Laser Melting and Selective Laser Sintering,

• Vat Photopolymerization also known as Stereolithography,

• Material Extrusion also known as Fused Filament Fabrication, Fused Deposition Modelling,

• Sheet Lamination,

• Directed Energy Deposition,

• Binder Jetting and

• Material Jetting.

 

In summary, Mahyar’s areas of expertise include:

• Design & Simulation

• Application Engineering

• Process & Material

• Post-Processing

• Measuring Quality

• Cost Estimation for AM process

• Process Parameters Optimization

• Material & Feedstock Selection

• Process Modeling and Prediction

• Micro and Macro-Scale Simulation

• Pre-process Considerations