Muhammad Usama S.

⇨ Mechanical Engineer with 15+ years of experience in product design, FEA/CFD simulations, and engineering consulting. ⇨ Specialized in developing high-performance designs, optimizing mechanical components, and applying AI and machine learning for engineering applications. ⇨ Completed 50+ projects across industries, including healthcare, renewable energy, and manufacturing. Key Skills: ✅Product Design & Development: CAD modeling, prototyping, material selection, and structural analysis ✅Finite Element Analysis (FEA): Stress, thermal, and fatigue analysis using ANSYS, Abaqus, and COMSOL ✅Computational Fluid Dynamics (CFD): Flow analysis for thermal management, filtration, and aerodynamics ✅AI & Machine Learning in Engineering: Predictive modeling for condition monitoring and failure analysis ✅Simulation & Optimization: Multiphysics modeling for structural, thermal, and mechanical systems ✅Renewable Energy Solutions: Solar PV system design, HVAC optimization, and water treatment solutions ✅Programming & Automation: Python, MATLAB, and engineering simulation scripting Services Offered: 1. 3D CAD modeling and design optimization 2. Structural and thermal analysis using FEA & CFD 3. AI-driven predictive maintenance and failure analysis 4. Engineering simulations for product validation 5. Water treatment and filtration system design 6. Renewable energy solutions (solar, HVAC, and thermal management) Notable Projects: 1. Foldable Electric Bicycle Design -Developed a compact and lightweight electric bicycle with a dual power system -Designed an FEA-validated aluminum frame and integrated a folding mechanism 2. Long-term Structural Analysis of a Polycarbonate Enclosure -Modeled creep behavior and interference-fit pin joints for a 26,000-hour performance study -Provided design recommendations for enhanced durability 3. Disposable Medical Product Optimization -Achieved 29.24% material savings while maintaining structural integrity -Improved cost efficiency for high-volume production 4. Machine Learning-Based Condition Monitoring for Bearings -Developed a high-accuracy AI model for fault detection using vibration data -Enabled predictive maintenance and cost reduction for industrial clients 5. High-Efficiency Ultrafiltration System for Industrial Wastewater -Designed a filtration system achieving 75.22% recovery with reduced energy consumption -Optimized the system for high-turbidity water treatment 6. Reverse Osmosis (RO) Plant for Textile Manufacturing -Designed a fully automated high-recovery RO system achieving 66% water recovery -Ensured regulatory compliance and reduced operational costs 7. Thermal Management System for Overclocked Nvidia GeForce 4090 -Developed an optimized serpentine channel water block for efficient GPU cooling -Reduced chip temperature to 48.91°C under full load 8. HVAC System Optimization for Commercial Buildings -Reduced cooling loads by 33.33%, leading to 29.6% cost savings -Designed energy-efficient multi-zone HVAC solutions 9. AI-Powered Predictive Modeling for Desalination Plants -Created machine learning models to optimize membrane area and energy consumption -Enhanced operational efficiency and reduced water treatment costs 10. Composite Material Development for Non-Silica Kitchen Countertops -Engineered epoxy-based composites with enhanced mechanical properties -Developed a cost-effective, environmentally friendly alternative to traditional materials Software & Tools * FEA & CFD: ANSYS Mechanical, ANSYS Fluent, ABAQUS, COMSOL Multiphysics, PolymerFEM, Digimat *3D CAD & Modeling: SolidWorks, AutoCAD, Fusion 360 *Programming & Data Analysis: Python, MATLAB, AI/ML modeling *Process Automation: Scripting for engineering workflows Education & Certifications PhD in Mechanical Engineering – King Fahd University of Petroleum & Minerals (2017) MS in Mechanical Engineering – King Fahd University of Petroleum & Minerals (2012) BE in Mechanical Engineering – National University of Science and Technology (2008) Why Hire Me? ✔ 14+ years of experience delivering high-quality engineering solutions ✔ Expert in product design, simulations, and AI-powered solutions ✔ Track record of 50+ successful projects with proven impact ✔ Commitment to quality and on-time project delivery Let’s Work Together! Looking for a reliable mechanical engineering expert? Let’s discuss your project! 📩 Contact me on Upwork to get started!