Abdul Khader Khan

About Abdul Khader Khan

Mechanical Engineer | 10+ years delivering precision engineering solutions across design, manufacturing, simulation, and process validation.I specialize in taking products from concept to production moving through design, rapid prototyping, FEA simulation, process validation, and into manufacturing. My work lives at the intersection of what\'s designed, what\'s simulated, and what\'s actually built always closing the gap between digital prediction and physical outcome.Core expertise: Design · Ansys · FEA · Additive Manufacturing · Process Validation · SolidWorks · Quality Engineering · DFM · Design Controls · Six Sigma · Materials ScienceMS in Mechanical Engineering. US Patent holder. CSWP certified.Open to: Mechanical Design · Manufacturing Engineering · R&D · Process Engineering · Simulation & FEA · NPD · Quality Engineering

Experience

1. Sr R & d Engineer

   Synopsys Inc

   Nov 2017 — Present · Salt Lake City, UT, US

   Developed non-equilibrium thermophysical property databases and material tuning workflows for AM materials, improving accuracy of Ansys Additive thermal simulations. • Engineered Additive Calibration Wizard in Ansys Mechanical using Python, automating strain scaling factor calibration and enhancing AM distortion prediction accuracy.• Wrote and executed IQ/OQ/PQ validation protocols for AM processes analyzing melt pool dimensions, porosity, and distortion data to identify root causes and implement corrective actions.• Developed and validated AM test methods, processing 3D scan data to capture dimensional distortion and validate simulation predictions against experimental results.• Created build file parsers and slice viewers to convert proprietary AM machine build files into Ansys-compatible format, streamlining simulation workflows.• Applied Six Sigma, LEAN, and DOE with statistical process control (SPC) to optimize AM manufacturing parameters and drive continuous improvement.• Served as AM process subject matter expert delivering training to engineering teams and external partners, managing cross-functional delivery via Azure DevOps.• Supported Ansys Additive software validation cycles requirements gathering, automated testing, bug verification, and QA collaboration.

Education

• University of Louisville

  Master’s Degree, Mechanical Engineering

  2015 — 2016

• Geethanjali High School

  High School, High School/Secondary Certificate Programs

  1994 — 2007

• Muffakham Jah College of Engineering & Technology, Osmania University

  Bachelor’s Degree, Mechanical Engineering

  2007 — 2011

Skills

• Simulations
• Emotional Intelligence
• Modeling
• Fluid Mechanics
• Engineering
• Autofab
• Aerospace
• Moldex 3d
• Solid Modeling
• Hypermesh
• Stress Analysis
• Cad/Cam
• Autocad Mechanical
• Management
• Pro Engineer
• Leadership
• Manufacturing
• Cad
• Data Analysis
• Product Design
• Catia
• Project Engineering
• Finite Element Analysis
• Testing
• Project Management
• Solidworks
• Gd&T
• Scanning Electron Microscopy
• Machine Design
• Microsoft Office
• Mechanical Engineering
• Magics
• Autocad
• Unigraphics
• Additive Manufacturing
• Ansys
• Ces Edupack
• Verification and Validation (V&V)
• Matlab