Mechanical Design & FEA
Mechanical Design & FEA
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Arash Azhang – Senior Design & Manufacturing Engineer | Additive | Mechanical | Biomedical
Close Continues Casting Mold
As a seasoned Mechanical Design Engineer and FEA Engineer, Arash Azhang brings more than a decade of experience turning concepts into robust, manufacturable products. He blends hands‑on CAD modelling, parametric design, and stress analysis to optimise structures across aerospace, energy, and biomedical sectors. Certified in SolidWorks and trained in Lean Six Sigma, Arash excels at bridging design and manufacturing, from early sketches to ISO‑compliant production lines.
Nose Pannell
Selected Design Projects
Selected Design Projects
What I do
What I do
Mechanical design & CAD modelling: Build detailed 3D CAD models using SolidWorks, CATIA V5, AutoCAD, Inventor and Creo, including sheet‑metal, injection‑moulded and machined components. Expert in GD&T, BS 8888 and ASME Y14.5 standards.
Finite‑element analysis: Perform static, dynamic, thermal and non‑linear FEA using Abaqus, ANSYS and SolidWorks Simulation to validate designs and predict failure modes. Use Python and Fortran scripting to automate simulations and accelerate design cycles.
Design for manufacture (DfM/DfA): Translate simulations into CNC‑ready drawings, ensuring manufacturability and cost efficiency. Collaborate with machining and fabrication vendors to iterate designs and integrate tolerance control and process validation.
Reverse engineering & digital twins: Reconstruct legacy parts using 3D scanning and build digital models that feed into digital twin environments for predictive maintenance and performance monitoring.
Key Projects
Key Projects
Furnace safety redesign – VIAN Steel Complex
Furnace safety redesign – VIAN Steel Complex
Implemented a FEM‑driven redesign of furnace components to improve safety and reliability. Using SolidWorks and Abaqus, Arash modelled thermal stresses and failure modes; the re‑engineered slag‑door and arm‑carrier systems achieved a 100 % safety rating and established a predictive‑maintenance framework for the plant.
Innovative Design Features
Enhanced Corrosion Resistance: Utilising cutting-edge materials, our bucket offers rust and corrosion resistance that surpasses industry standards.
Superior Slag Repellence: The bucket’s smooth, non-stick surface makes slag removal easy, minimizing downtime and maintenance requirements.
Reinforced Structure: Strategic reinforcement in high-stress areas provides additional strength where needed most, allowing the bucket to handle heavy loads without compromise.
Optimised Shape: The bucket’s geometry has been meticulously designed to facilitate efficient loading and unloading and enhance extended corrosion resistance time.
Benefits of Our Special Loader’s Bucket:
Increased Operational Efficiency: Our bucket’s robust construction and corrosion-resistant properties ensure continuous operation without the need for frequent replacements or repairs.
Cost-Effectiveness: Over time, the extended service life and reduced maintenance requirements translate into significant cost savings.
Safety Assurance: The integrity of our bucket’s design minimises the risk of structural failure, ensuring a safer work environment for your team.
Embrace the power of innovation and resilience with our special loader bucket, the ultimate solution for the steel industry’s most demanding applications. Contact us today to learn more and elevate your operations to new heights of efficiency and reliability.
Decoding Gears: A Journey Through Reverse-Engineering
Decoding Gears: A Journey Through Reverse-Engineering
Under the leadership of Arash Azhang, Vian Company has leveraged advanced reverse engineering in gear system design to deliver measurable operational benefits. By extracting and defining precise manufacturing parameters, Arash has enabled solutions that significantly reduce maintenance costs and eliminate the need to purchase entire gear systems. This approach not only drives cost efficiency but also enhances reliability and extends the lifecycle of critical equipment, positioning projects to outperform industry benchmarks consistently.
Under the leadership of Arash Azhang, Vian Company has leveraged advanced reverse engineering in gear system design to deliver measurable operational benefits. By extracting and defining precise manufacturing parameters, Arash has enabled solutions that significantly reduce maintenance costs and eliminate the need to purchase entire gear systems. This approach not only drives cost efficiency but also enhances reliability and extends the lifecycle of critical equipment, positioning projects to outperform industry benchmarks consistently.
One part of Crane 75 ton gear system
Eltra Elemental Analyzer’s gear system
Simulation‑driven performance improvement – Azhangostar
Simulation‑driven performance improvement – Azhangostar
Delivered simulation‑driven design and reverse‑engineering projects that increased product performance by 20 % and reduced analysis time by 30 % through Python automation. Provided DfM‑compliant drawings and supplier documentation for CNC production.
Project Case Study: Granular Material Flow Simulation (SolidWorks)
Project Case Study: Granular Material Flow Simulation (SolidWorks)
Mechanical Design • Simulation • Material Behaviour
A simplified SolidWorks simulation to analyse how granular material (iron-ore representation) flows and stabilises across different slope angles. Demonstrates practical simulation skills, CAD modelling capability, and engineering judgement in predicting physical behaviour.
SolidWorks simulation of simplified granular material to evaluate flow behaviour and optimise slope geometry.
What I Did:
What I Did:
- Created simplified 3D granular shapes in SolidWorks
- Simulated flow behaviour under gravity across multiple slope angles
- Evaluated stability, sliding tendencies, and packing behaviour
- Extracted insights to support material-handling and slope-geometry decisions
Tools: SolidWorks CAD, Motion Study, Contact & Gravity Simulation
Tools: SolidWorks CAD, Motion Study, Contact & Gravity Simulation
Keywords: mechanical simulation, slope stability, SolidWorks analysis, granular modelling
Keywords: mechanical simulation, slope stability, SolidWorks analysis, granular modelling
Why It Matters:
Why It Matters:
Showcases the ability to use simulation for quick, early-stage design validation, understand material behaviour trends and support engineering decisions, valuable in mechanical design, R&D, process optimisation and advanced manufacturing roles.
Showcases the ability to use simulation for quick, early-stage design validation, understand material behaviour trends and support engineering decisions, valuable in mechanical design, R&D, process optimisation and advanced manufacturing roles.
Valve assembly optimisation – ABA ONE
Valve assembly optimisation – ABA ONE
Designed fluid‑system components and valve assemblies with SolidWorks and ANSYS; implemented FEA to identify stress concentrations, resulting in a 30 % performance improvement and enabling actuator automation.
A Success Story
Arash Azhang successfully redesigned the component, increasing capacity from 16 to 24 bars, a 50% improvement in performance. This achievement demonstrates advanced engineering capability, delivering measurable gains in safety, reliability, and operational efficiency. For recruiters and industry leaders, it highlights a proven ability to drive innovation, optimisation, and high‑impact results in critical systems.
Simulation and Analysis
Simulation and Analysis
Finite Element Analysis (FEA)
Using FEA software, I simulated the hook’s behavior under various loads.
Stress distribution maps guided further design refinements.
Validation Testing
I fabricated prototypes (Design Forge Mold) based on the optimised design.
Hydrostatic tests were conducted to measure failure points.
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