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

Research & Achievements

Advance Bi-material Simulation

Arash Azhang is a Research & Development Engineer whose work spans mechanical engineering, additive manufacturing and biomedical device innovation. His research agenda blends finite‑element analysis (FEA), process optimisation and thermomechanical modelling to solve complex problems for aerospace, energy and healthcare sectors. As a patent holder and award‑winning designer, he translates academic insight into tangible, commercially viable technologies.

Patent innovation

Signature Research Projects

Thermomechanical modelling of bi‑material WAAM deposition

For the EU MULTI‑FUN project, Arash developed FEA‑based process models to predict crack initiation and stress evolution during Wire Arc Additive Manufacturing (WAAM) of Invar–Copper components. His simulations informed process‑window parameters and helped industry partners mitigate thermal stresses in hybrid metallic systems, advancing directed‑energy deposition technology.

Furnace redesign & predictive maintenance

At VIAN Steel Complex, he led a FEM‑driven redesign of furnace components to enhance safety and reliability. Through failure analysis and stress modelling, the team achieved a 100 % safety rating and established a predictive‑maintenance framework that reduced downtime and operator risk.

Cold‑Wire GMAW process optimisation

As part of a Christof Group SBN initiative, Arash collaborated with researchers at Cranfield University to optimise Cold‑Wire Gas Metal Arc Welding (GMAW) parameters for super‑duplex stainless steels. The resulting process model correlated heat input, rolling, and deposition efficiency, providing the industry with a roadmap for high‑deposition additive manufacturing.

Biomechanics & implant optimisation

Arash’s MSc thesis, “Mechanical Behaviour and Optimisation of Orthopaedic Implants During Bone Healing,” combined experimental data with FEA to study stress distribution and fracture risk. His subsequent work on orthopaedic devices improved biocompatibility by 60 % through surface optimisation and led to multiple peer‑reviewed publications.

Evaluation of residual stress

When surgeons reshape bone plates to fit a patient’s anatomy, each bend introduces residual stress that can weaken the implant. Our research, Impact of residual stress on the bone plate during the surgical plating process, and this work bridges engineering and medicine, offering actionable knowledge for decision‑makers who want to ensure patient safety while driving innovation in implant design.

Awards, conferences, publications

Patent innovation: Invented a polymeric weld‑pipe configuration that enhanced fluid‑sealing performance; protected under Patent No. 139350140003007761.
Design awards: Won the 2023 STEM Design Bronze Medal for an industrial component modelled in SolidWorks, applying advanced drafting and DfM principles to demonstrate manufacturability.
Performance improvements: Delivered simulation‑driven design projects that boosted performance by 20 % and cut analysis time by 30 % through Python automation.
Quality & compliance: Produced ISO 13485‑compliant technical files for 23 orthopaedic implant categories and supported aerospace component qualification with precision FEA and defect analysis.
Research dissemination: Presented findings at international conferences (European Society of Biomechanics) and authored ISI‑indexed papers on additive manufacturing and implant optimisation.

Bronze Medal, SolidWorks Design Competition

Hosted Technical and Vocational Training Organisation
Competed against top-tier industrial companies from 22 provinces
Demonstrated expertise in SolidWorks and precision industrial design

Comparative Study of Cold-Worked vs. Forged Hip Screw Systems (Sage Journals)

Research on implant performance and reliability, combining experimental validation with advanced modelling. Demonstrates my contribution to safer, more effective orthopaedic device design.

Biomechanical Investigation of Bone Screw Head Design for Extracting Stripped Screw Heads: Integration of Mechanical Tests and Finite Element Analyses - PubMed

Peer‑reviewed study integrating mechanical testing and finite element analysis to improve orthopaedic screw extraction. Highlights my expertise in simulation‑driven biomedical design and ISO 13485‑compliant development.

Continuous Casting Mould Redesign with INTECO Group (Austria)

Arash Azhang partnered with INTECO Group, Austria, to reverse engineer and redesign a close-continuous casting mould. His role focused on reviewing new drafts, defining correct tolerances for manufacturability, and evaluating workshop production.

The collaboration delivered a mould system with improved cooling efficiency, extended service life, and compliance with industrial standards. This project highlights Arash’s ability to combine precision design, manufacturing readiness, and international collaboration to achieve practical, future‑ready solutions.

Why it Matters

Commercial impact: Arash’s research delivers measurable outcomes—such as safety improvements, performance gains and biocompatibility enhancements that translate directly to better products and processes.

Cross‑sector versatility: Experience spanning aerospace, energy, additive manufacturing and biomedical devices demonstrates adaptability and breadth.

Innovation mindset: Patents, awards and published research signal a commitment to pushing boundaries and generating intellectual property.

Collaboration & leadership: Proven ability to work with multidisciplinary teams, manage R&D projects and communicate results to both technical and non‑technical stakeholders.

Get in Touch

If your organisation seeks a research engineer or R&D specialist who can develop new processes, optimise manufacturing and deliver patented innovations, connect with Arash Azhang. His blend of analytical modelling, experimental validation and industry collaboration makes him a valuable partner for driving innovation and achieving measurable impact.

Page updated

Google Sites

Report abuse