Ahmed Ashraf

Performed 10+ structural and dynamic FEA simulations (static, modal, harmonic, fatigue) across industrial machines including trommels, conveyor systems, and destoner units. Diagnosed a resonance risk on a destoner support frame, confirming a safety factor of 2.7 via modal and harmonic analysis. Compared two structural cross-sections for a 12-ton trommel screen frame, selecting the design with 22% lower combined stress and a Factor of Safety of 2.96.

Designed and integrated mechanical systems for RO desalination plants in SolidWorks — 3D assemblies, structural frameworks, and piping routing. Performed structural FEA (ANSYS Workbench) on pressure vessels and water separation walls to verify load-bearing capacity under hydrostatic pressure. Developed MATLAB scripts to optimize intake screen geometry, maximizing flow rate and minimizing pressure drop.

Created accurate 3D SolidWorks models of electronic components directly from datasheets. Adjusted dimensions and tolerances to match exact manufacturer specifications. Delivered models fully compatible with PCB design workflows.

Mentored new team members on core design principles — material selection, fabrication, power transmission, and SolidWorks/FEA best practices. Individually engineered and optimized the Tri-Wheel Climber mechanism, enabling the robot to overcome 20 cm steps. Resolved legacy design issues through stress analysis and motion simulation. Oversaw full robot integration, testing, and design reviews for ABU Robocon 2023 in Phnom Penh, Cambodia.

Led end-to-end development of the ABU Robocon 2022 Shooting Mechanism — from concept to a 12-meter accurate ball-projection system. Fabricated and tested 15+ prototypes, achieving 95% assembly success and 95% throwing accuracy. Resolved critical failures through iterative testing, raising system reliability from 60% to 92%. Standardized CAD documentation for fabricators and manufacturing workflows.