Arash Azhang – Senior Design & Manufacturing Engineer | Additive | Mechanical | Biomedical

Additive Manufacturing & WAAM

With more than 12 years of bridging research, design, and production, Arash Azhang specialises in Wire Arc Additive Manufacturing (WAAM) and related metal additive and welding processes. Dual‑qualified with MSc degrees in Metal Additive Manufacturing and Biomechanics, he translates advanced simulation and research into safe, manufacturable solutions that meet ISO 13485 and AS 9100 requirements. His work spans thermomechanical modelling, process optimisation, quality assurance, and Lean Six Sigma–driven risk management.

Highlights

FEA‑based WAAM process modelling (Cranfield University)

Developed thermomechanical finite‑element models for bi‑material deposition of Invar–Copper using WAAM.
Predicted crack initiation and stress evolution across the solidification interface; findings informed process‑window parameters for the EU MULTI‑FUN project, strengthening industrial understanding of thermal‑stress mitigation in hybrid metallic systems.
Used Python automation and Abaqus/Fortran scripting to perform parametric studies, validating models against experimental data.

Bi-material Simulation.mp4

Invar-Copper Simulation

WAAM3D aerospace qualification (WAAM3D Ltd.)

As a part‑time Additive Manufacturing associate, supported Airbus landing‑gear qualification by performing FEA‑based dimensional analysis, dye‑penetrant testing and simulation–experiment correlation.
Conducted process calibration and monitoring for aerospace‑grade WAAM depositions and refined tolerance‑control protocols to improve defect‑detection reliability.
Coordinated collaboration between research and industrial partners, ensuring that WAAM‑developed parts met certification requirements.

Process optimisation for super‑duplex stainless steels (Christof Group SBN project)

Collaborated with Cranfield University’s multidisciplinary team to optimise Cold‑Wire GMAW parameters for super‑duplex stainless steels.
Established a process model correlating heat input, rolling, and deposition efficiency, forming the basis for an industrial high‑deposition roadmap.
Applied lessons learned to other WAAM applications, reducing porosity and enhancing microstructural integrity.

Results

This project demonstrates how interlayer rolling during CW‑GMA welding represents a significant advancement in the processing of super duplex stainless steel (SDSS). By effectively encouraging austenite formation and markedly increasing dislocation density, the technique achieves a notable refinement of the microstructure. These microstructural developments directly contribute to greater strength and hardness, ensuring SDSS components deliver improved performance in demanding industrial environments. The evidence confirms that in‑process rolling is not merely a promising approach but a practical and scalable solution for enhancing the material properties of SDSS. For recruiters and industry leaders, this work highlights a forward‑looking contribution to materials engineering, welding innovation, and performance optimisation, all vital areas for driving next‑generation product development and maintaining competitive advantage.

Build Cycle Strategy

Arash Azhang developed a comprehensive Build Cycle Strategy for aerospace‑grade Ti64 structural brackets, ensuring full alignment with Quality Management System (QMS) standards and international aerospace specifications. His methodology encompassed the entire production lifecycle, from component selection and build cycle layout to witness testing requirements, establishing a clear pathway for compliance and reliability. By integrating ultrasonic (UT) and computed tomography (CT) evaluations with finite element analysis (FEA), he defined rigorous acceptance criteria that safeguard part integrity. In addition, Arash implemented statistical process control (SPC) to monitor critical parameters, driving consistency, repeatability, and measurable quality improvements. This strategy not only enhances material performance and structural reliability but also demonstrates his ability to combine engineering excellence with regulatory compliance. For recruiters and industry leaders, the project highlights Arash’s forward‑thinking contribution to aerospace innovation, quality assurance, and process optimisation, reinforcing his value as a professional who delivers solutions that strengthen both operational efficiency and long‑term competitiveness.

Core Expertise & Tools

Additive manufacturing processes: Wire Arc Additive Manufacturing (WAAM), Cold‑Wire GMAW development, and in‑process rolling deposition.
Thermomechanical modelling & simulation: Finite‑element analysis using Abaqus, ANSYS and SolidWorks Simulation; Python and Fortran automation; validation to ASTM/BS standards.
Process control & quality: Residual‑stress analysis, defect prediction, NDT integration (visual, dimensional, surface characterisation), and lean Six Sigma methodologies.
Multidisciplinary collaboration: Skilled at translating research findings into industrial practice and mentoring engineers to implement WAAM and welding technologies.

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