Ahmad Adil | Projects

Sep 2025 – Present

Conducting MSc thesis research on the compressive failure behaviour of fibre-reinforced composites, using finite element analysis of real microstructural geometries.
Processing micro-CT scan data from composite specimens to extract representative volume elements (RVEs) as FE model inputs.
Building and running Abaqus simulations to capture fibre kinking, matrix cracking, and interface debonding under longitudinal compressive loading.
Comparing simulation results against experimental data to validate model accuracy and identify failure initiation sites.

Sep 2025 – Apr 2026

Designed a 12-speed forward, 3-speed reverse gearbox for a 40-tonne commercial truck, rated at 2100 Nm input torque, 2200 RPM, and a 750,000-mile warranty life.
Developed a 2×3×2 twin-countershaft architecture — front splitter, main box, and rear range group — to optimise shaft loading and bearing life within mass and cost constraints.
Sized gear pairs, shafts, and bearings through static calculations in Excel, achieving critical speed margins of at least 4× and bearing selections rated for 10⁹ cycles at 99% reliability.
Delivered a complete gearbox design within client constraints of 484 kg total mass and £10,000 manufacturing cost.

Jan 2026 – Mar 2026

Simulated turbulent airflow around an Ahmed body using STAR-CCM+, systematically comparing 5 turbulence models including k-ε, k-ω SST, and Reynolds Stress Model across multiple wall treatments.
Conducted a mesh independence study up to 2 million cells, selecting a polyhedral mesh after identifying convergence failures with structured hexahedral meshes.
Identified k-ω SST with low y+ wall treatment as the most accurate model, achieving the closest agreement with published experimental velocity and turbulent kinetic energy profiles.
Investigated the effect of rear slant angle (25, 30, 35 degrees) and free-stream velocity (8.5 to 50 m/s) on drag and lift coefficients, with results consistent with published vehicle aerodynamic data.
Wake features and velocity profiles were in excellent agreement with the seminal paper on Ahmed body wake characteristics.

Sep 2025 – Jan 2026

Redesigned a legacy brass casting into a CNC-machinable form and defined the full manufacturing process for 600 parts per year.
Programmed the full machining sequence in SolidWorks CAM, selecting Haas machine tools and Sandvik Coromant tooling to suit material and process requirements.
Produced full manufacturing documentation — CNC setting sheets, a production plan, and a Bill of Materials — to support controlled manufacture.
Costed the process using a finite capacity model covering machine depreciation, labour, space, power, and consumables.

Oct 2025 – Nov 2025

Redesigned the steering wheel in SolidWorks through iterative material removal guided by stress concentration analysis, achieving an 18% weight reduction while meeting structural targets.
Produced manufacturing drawings for 3 components and supported fabrication using waterjet cutting and FDM 3D printing in coordination with the workshop team.

Jan 2025 – Feb 2025

Reverse-engineered a TEMA shell-and-tube heat exchanger from OEM general assembly drawings, building a detailed 600+ component SolidWorks assembly with all threads and assembly interfaces captured.
Generated photorealistic renders using SolidWorks Visualize to communicate planned design modifications to stakeholders and support approval for upgrade work.
Presented proposed modifications at an interdepartmental meeting, gathering cross-functional comments to inform the final upgrade decision.

Jun 2024 – Jul 2024

Modelled and assembled a 700+ component turbojet engine from scratch in SolidWorks, focusing on component fits, interfaces, and overall mechanical layout.
Managed assembly complexity through sub-assemblies, CAD mates, and performance optimisation settings, modelling multiple exhaust nozzle configurations.
Produced photorealistic renders using SolidWorks Visualize to communicate the design.

Sep 2023 – Jun 2024

Designed a 2-DOF bionic ankle-foot prosthesis as a group senior year project, awarded 1^st place in the faculty.
Applied first-principles beam bending analysis and Ashby chart material selection to identify PETG as the optimal material based on specific strength, chemical resistance, and cost.
Produced SolidWorks CAD models and manufacturing drawings, iterating through 4 design cycles to resolve structural, actuation, and joint clearance issues.
Verified structural integrity via static and dynamic structural analysis, achieving a safety factor of 2.5.
Fabricated the prototype in PETG via FDM 3D printing, integrating a NEMA-17 stepper motor and dual IMU sensors for closed-loop gait adaptation.

Oct 2023 – Dec 2023

Designed a suspension-based wheel module for a space rover as part of a national prototyping competition, achieving 3^rd place.
Modelled the wheel in SolidWorks to competition constraints: 6-inch diameter, 2-inch width, 3 to 6 spokes, and a central hub for load application, with spoke geometry optimised to provide 1 to 5 mm z-direction deflection under load.
Performed static structural FEA under an 80 N load to validate load-bearing capacity and confirm deflection within specification, iterating the design across multiple cycles to minimise mass.
3D printed the final prototype in PLA via FDM, achieving a wheel mass of 163 g.

Sep 2022 – Jun 2023

Designed and built an H-frame quadcopter as part of a group project, managing a team of 15 over 6 months from concept to competition-ready prototype.
Focused on a lean design to maximise payload capacity.
Selected carbon fibre tubes and biodegradable FDM-printed components based on stiffness-to-weight requirements, achieving a 15 kg MTOM with a 40-minute flight time at a top speed of 15 m/s.
Validated structural integrity through FEA and produced full manufacturing drawings for fabrication.
Competed at the 2024 RoboNation SUAS Competition (USA), achieving 4th place in mission ranking among 70+ international teams.