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Al Mazedur Rahman

I am Postdoctoral Researcher, Material Characterization, Additive Manufacturing, Sensor Integration, Lean Engineering

Work Experience

Empowering Creativity through

May 2025 - Present (3 months)

Texas A&M University

Postdoctoral Researcher

I am working with Dr. Alaa Elwany on a DARPA-funded initiative aimed at revolutionizing the certification of 3D-printed metal components through real-time sensor integration, AI-powered defect detection, and microstructure-informed performance prediction.

January 2021 - May 2025 (5 years)

Texas A&M University

Research Assistant

• Designed and engineered high-precision 3D printed parts using SolidWorks and PolyJet/binder-jet/LPBF printers for advanced AM subsystems, enhancing usability and reliability, and reducing print defects by 30%

• Characterized and analyzed biomass-fungi composites, titanium- and stainless-steel-infused polymer filaments using SEM, rheology, FTIR, DSC, TGA, and thermal conductivity methods to optimize material performance

• Performed powder morphology and granulation studies; calibrated printing parameters to fabricate custom grinding tools

• Led procurement and ROI evaluation for over $300,000 in laboratory instrumentation; designed the layout and established a 500 sq. ft. lab, developed SOPs, and implemented maintenance protocols, achieving 0% equipment downtime over 4 years

• Conducted FEA and CFD simulations; machined and prototyped subsystem components using CNC and additive manufacturing processes; generated detailed BOMs to support design transfer to industry

August 2024 - January 2025 (6 months)

National Renewable Energy Laboratory

Intern

• Conducted LCA, sensitivity, and uncertainty analysis of 3D printed biomass-fungi composites using SimaPro and Python, assessing decarbonization potential, and environmental impact

• Investigated in-depth techno-economic analysis (TEA) to assess the economic feasibility, decarbonization potential, and scalability of a new product introduction (NPI), resulting in an estimated 18% cost reduction in large-volume production

May 2022 – August 2022 (3 months)

Texas A&M University

Project Lead for Industry Collaboration project

• Led a $100K end-to-end industrial collaboration project within 3 months, managing a cross-functional team of 5 to evaluate radiation effects on Alcon packaging materials and oversee project budgeting • Designed custom fixtures and defined product specifications and test methods for measuring durability under radiation exposure • Conducted 5 ASTM standard tests and performed detailed data analysis, failure mode and effects analysis, presented findings to industry partners, contributed to deciding on a $150M investment

August 2021 – May 2025 (4 years)

Texas A&M University

Teaching Assistant

Course IDIS 450: Analytics for Distribution Operation

• Designed and implemented an AI/ML curriculum for over 540 trainees, integrating real-world applications • Instructed data visualization, SPC, process simulation, and KPI monitoring, ensuring trainees gain industry-relevant skills

Course ISEN 281: Essentials of Modern Manufacturing Methods for Engineering Design

• Delivered hands-on training to 360+ students on CNC machining, BOM creation, and SolidWorks design with 0 safety incidents. Developed scalable lab protocols and training modules • Developed process mapping strategies, GD&T, GR&R, and simulation exercises aligned with modern manufacturing scenarios to build core competency in DFM/DFA principles

January 2019 – December 2020 (2 years)

University of Texas Rio Grande Valley

Research Assistant

• Investigated process parameter effects on CVD-coated thin films, designed and prototyped custom fixtures and tooling

• Applied microscopy and spectroscopy such as SEM, XPS, for molecular analysis and characterization of thin film samples

• Performed root-cause failure analysis using SEM, XRD, EDS, and profilometry. Identified degradation mechanisms in titanium alloy milling and implemented design corrections that improved tool life by 55%, and reduced surface roughness by 6%

My Skills

Core competencies that drive my performance.

My Skills

LPBF100 %

Sensor integration98 %

Binder Jetting %

FDM94 %

Rheology100 %

SolidWorks100 %

JMP100 %

GD&T80 %

CNC90 %

Finite Element Analysis80 %

CFD (ANSYS Fluent)80 %

Materials Characterization and Analysis90 %

Lean Six Sigma, SOP, WIS, JIT, TQM, 8 Waste, A3 Projects, VSM, 5S, Kanban, CTQ, SMED80 %

Fusion 360100 %

Engineering Drawing100 %

Fixture Design90 %

BOM Development90 %

Python (NumPy, Pandas, Deep Learning, TensorFlow, Seaborn)100 %

R100 %

EBSD100 %

SEM80 %

XRD90 %

FTIR90 %

DSC90 %

TGA90 %

DMA90 %

Education

Empowering Creativity through

January 2021 - May 2025

Doctor of Philosophy - PhD

Texas A&M University

Lorem Ipsum has been the industry's standard dummy text ever since the 1500s, when an unknown printer took a galley of type and scrambled it to make a type specimen book.

2019 - 2020

Master of Science - MS

The University of Texas Rio Grande Valley

Lorem Ipsum has been the industry's standard dummy text ever since the 1500s, when an unknown printer took a galley of type and scrambled it to make a type specimen book.

2013 - 2017

Bachelor of Science - BS

Khulna University of Engineering and Technology

Lorem Ipsum has been the industry's standard dummy text ever since the 1500s, when an unknown printer took a galley of type and scrambled it to make a type specimen book.

Google Scholar Profile

I have published 20 peer-reviewed articles and presented at 4 major conferences in Additive Manufacturing domain.