Iftekhar Islam, PhD

Experience

• 

  Walton Hi-Tech Industries PLC.

  Jun 2007 - Apr 2008

  Mechanical Design Engineer, Motorcycle Body Structure

  • Led design team for 3D modeling and performed FEA for chassis, seats, fuel tanks, fixtures, etc.• Developed motorcycle structural components from concept through the production process • Conducted theoretical study, benchmark, and developed load cases for failure analysis.• Trained technical groups for quality control (QC) & continuous improvement(CI)• Led product development team in troubleshooting by performing RCA, DMAIC/DMADV, etc.

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  Biman Bangladesh Airlines

  Apr 2008 - Aug 2012

  Assistant Manager, Aerospace Structure

  • Developed procedures to maintain airframe and engine structural durability and performance.• Established SOP and testing documents for aircraft to safeguard structural airworthiness• Performed FEA (Abaqus), CFD (Fluent) to predict the integrity of repaired parts. • Conducted training need analysis for technical persons on aircraft checks and maintenance. • Performed theoretical load response study of aircraft structures for the composite patch repair process

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  North Carolina A&T State University

  Aug 2012 - May 2018

  • Developed a process for making nanofiber enhanced composite with reduced delamination properties• Established curing parameters for developing a composite with desired physical properties• Designed composite manufacturing molds with DFM, DFA considerations • Optimized electrospun nanofiber dispersion process by DFMEA for a prepreg manufacturing• Conducted mechanical integrity testing for products with different material compositions• Applied statistical techniques DoE, Regression Analysis etc. for process design• Performed structural analysis by Finite Element Method (ANSYS, Abaqus, Hypermesh)• Conducted mechanical integrity testing for products with different material compositions Show less

  • Graduate Research Assistant, Composite Structure

    Jan 2014 - May 2018

  • Graduate Research Assistant, Intelligent structure and Smart materials

    Aug 2012 - Dec 2013
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  Rivian

  Jul 2018 - Jul 2022

  • Identified failure modes and developed robust structure design & evaluation criteria EV parts• Developed new methods for evaluating material performance variation at different loading environments• Optimized RoDip thermal process conditions for the best dimensional quality and desired mechanical functionality• Developed, integrated, and standardized component, subsystem virtual tests by knowledge capture schemes• Estimated structural design safety factor affected by manufacturing processes and assembly variables. Tools: ANSA, Abaqus, hand calculation, free body diagram, DMAIC, RCA, PPS etc. Show less • Evaluated EV part designs for durability load cases by static (linear and nonlinear), dynamic and fatigue & thermal FEA analysis. Proposed necessary geometry, connections, and materials for designs.• Developed durability material database for FEA analysis of EV body structures with metallic, nonmetallic parts• Obtained detail welding modeling method for failure prediction in heat affected zone (HAZ) and weld zone• Developed test methods and performed benchmarking study for hood torsional, lateral stiffness and performed correlation study between CAE prediction and actual test.• Devised method to implement Fluid Structure Interaction (FSI) by using CFD data to implement FEA modeling. Optimized hood, roof, header applique and spoiler designs for worst aerodynamic loading. • Performed optimization study for body exterior (fascia, wheel liner, spats) structure and connection requirement for water fording load case. The project was aimed to enhance DFM and DFA and minimize cost. • Standardized accelerated duty cycle and attribute ratings and developed different durability targets by loading data and detailed hand calculation. Also, developed chassis load distributor based on critical loadings.• Interpreted structural regulatory requirement for trailer hitch and developed load case compliance criteria.• Conducted design integrity checks for different EV powertrain shafts and gears at different press fit conditionsTools: ANSA, Abaqus, LS Dyna, nCode, etc. Show less

  • Sr. Durability Methods Engineer

    Jul 2021 - Jul 2022

  • Structural Durability Engineer

    Jul 2018 - Jul 2021
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  GE Aerospace

  Sept 2022 - Jan 2023

  Sr. Engr- Mechanical Component (Production Technology)

  • Investigated material review board (MRB) for rotary component designs in advanced gas turbine structures• Assessed manufacturing nonconformity and their physical performance variations from nominal designs by FEA • Develop repair and rework guidelines by FEA tools to reduce part scrap events and minimize unit production cost • Provided design for producibility & design for processability insight feedback to product team & program managementTools: Ansys, Hypermesh, Siesta, Fracture mechanics, Stress sensitivity factors, GD&T Show less

• 

  General Motors

  Jan 2023 - now

  VDDV Engineer Body Exterior

  • Led virtual validation process for low-speed impact and towing performance for different market segments• Led virtual performance evaluation for body exterior load cases for Equinox EV, Blazer EV, Celestiq EV, Sollei EV etc. that includes solar, thermal, towing, ocean shipping, modal, PKE, FSI etc. • Led low speed impact FMVSS 581, GB 17354 virtual test and correlation procedure for robust prediction • Led reclassification effort for vehicles by developing curb impact load case to comply CAFÉ regulation • Led sonic weld modeling method by introducing energy-based failure criteria and optimized joint design • Led virtual validation procedure for towing, and low speed regulation requirements to save physical test expense• Controlled folder structure for workspace and manage data based on business and regulatory need• Established material card need and physical coupon test need for the different kinds of simulation • Developed variational study to capture different test conditions affecting vehicle performance • Served as the Emergency Workgroup Coordinator for the team and involved in community outreach activities Tools: Hand calculation, ANSA, Meta, Optistruct, LS Dyna, nCode, etc. Show less