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Wadea Ameen Qaid
College of Engineering and Architecture

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Preprint content
Published: 15 June 2021
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Electron-beam melting (EBM) is a rapidly developing metal additive manufacturing (AM) method. It is more effective with complex and customized parts manufactured in low volumes. In contrast to traditional manufacturing it offers reduced lead time and efficient material management. However, this technology has difficulties with regard to the construction of overhang structures. Production of overhangs using EBM without support structures results in distorted objects, and the addition of a support structure increases the material consumption and necessitates post-processing. The objective of this study was to design support structures for metal AM that are easy to remove and consume lower support material without affecting the quality of the part. The design of experiment methodology was incorporated to evaluate the support parameters. The multi-objective optimization minimizing support volume, support removal time along with constrained deformation was performed using multi objective genetic algorithm (MOGA-II). The optimal solution was characterized by a large tooth height (4 mm), large tooth base interval (4 mm), large fragmented separation width (2.5 mm), high beam current (6 mm), and low beam scan speed (1200 mm/s).

ACS Style

Wadea Ameen Qaid; Abdulrahman Al-Ahmari; Muneer Khan Mohammed; Husam Kaid. Multi-Objective Optimization of Support Structures for Metal Additive Manufacturing. 2021, 1 .

AMA Style

Wadea Ameen Qaid, Abdulrahman Al-Ahmari, Muneer Khan Mohammed, Husam Kaid. Multi-Objective Optimization of Support Structures for Metal Additive Manufacturing. . 2021; ():1.

Chicago/Turabian Style

Wadea Ameen Qaid; Abdulrahman Al-Ahmari; Muneer Khan Mohammed; Husam Kaid. 2021. "Multi-Objective Optimization of Support Structures for Metal Additive Manufacturing." , no. : 1.

Journal article
Published: 17 March 2021 in Metals
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Additive manufacturing (AM), particularly electron beam melting (EBM), is becoming increasingly common in the medical industry because of its remarkable benefits. The application of personalized titanium alloy implants produced using EBM has received considerable attention in recent times due to their simplicity and efficacy. However, these tailored implants are not cost-effective, placing a tremendous strain on the patient. The use of additional materials as support during the manufacturing process is one of the key causes of its high cost. A lot of research has been done to lessen the use of supports through various types of support designs. There is indeed a noticeable paucity of studies in the literature that have examined customized implants produced without or minimal supports. This research, therefore, reports on the investigation of cranial implants fabricated with and without supports. The two personalized implants are evaluated in terms of their cost, fabrication time, and accuracy. The study showed impressive results for cranial implants manufactured without supports that cost 39% less than the implants with supports. Similarly, the implant’s (without supports) build time was 18% less than its equivalent with supports. The two implants also demonstrated similar fitting accuracy with 0.2613 mm error in the instance of implant built without supports and 0.2544 mm for the implant with supports. The results indicate that cranial implants can be produced without EBM supports, which can minimize both production time and cost substantially. However, the manufacture of other complex implants without supports needs further study. The future study also requires a detailed review of the mechanical and structural characteristics of cranial implants built without supports.

ACS Style

Khaja Moiduddin; Syed Mian; Wadea Ameen; Hisham Alkhalefah; Abdul Sayeed. Feasibility Study of the Cranial Implant Fabricated without Supports in Electron Beam Melting. Metals 2021, 11, 496 .

AMA Style

Khaja Moiduddin, Syed Mian, Wadea Ameen, Hisham Alkhalefah, Abdul Sayeed. Feasibility Study of the Cranial Implant Fabricated without Supports in Electron Beam Melting. Metals. 2021; 11 (3):496.

Chicago/Turabian Style

Khaja Moiduddin; Syed Mian; Wadea Ameen; Hisham Alkhalefah; Abdul Sayeed. 2021. "Feasibility Study of the Cranial Implant Fabricated without Supports in Electron Beam Melting." Metals 11, no. 3: 496.

Research article
Published: 22 December 2020 in Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications
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Electron beam melting technology offers various benefits like the reduced product cycle time, customization, flexibility, high energy density and less material wastage. However, electron beam melting still suffers from redundant usage of support structure material while fabricating overhang structures. The support structures not only consume additional material, but also require additional time for their design and removal. The optimized support structures have to be designed in such a way that they consume minimum material, are easy to remove and are free from defects. The aim of the current study is to study the effect of support design and process parameters on the performance of the support structures (cost and quality) during additive manufacturing of Ti6Al4V alloy via electron beam melting. The results show that the support structures parameters play a significant role in the cost of the applied support and the accuracy of the fabricated object. It was found that with appropriate selection of support design and process parameters, it is possible to reduce the support volume and hence the fabrication cost in metal additive manufacturing (AM). A tooth height of 3 mm, no support offset of 2 mm, and fragmentation separation width of 0.8 mm resulted in lower support volumes without having any effect on the quality of the overhang. This study systematically investigated the support structure design and their outcomes on overhang fabrication. Its conclusions could add value to the researchers working on additive manufacturing of Ti6Al4V alloy by electron beam melting.

ACS Style

Wadea Ameen; Muneer Khan Mohammed; Abdulrahman Al-Ahmari; Naveed Ahmed; Syed Hammad Mian. Investigation of support structure parameters and their affects during additive manufacturing of Ti6Al4V alloy via electron beam melting. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 2020, 1 .

AMA Style

Wadea Ameen, Muneer Khan Mohammed, Abdulrahman Al-Ahmari, Naveed Ahmed, Syed Hammad Mian. Investigation of support structure parameters and their affects during additive manufacturing of Ti6Al4V alloy via electron beam melting. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications. 2020; ():1.

Chicago/Turabian Style

Wadea Ameen; Muneer Khan Mohammed; Abdulrahman Al-Ahmari; Naveed Ahmed; Syed Hammad Mian. 2020. "Investigation of support structure parameters and their affects during additive manufacturing of Ti6Al4V alloy via electron beam melting." Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications , no. : 1.

Journal article
Published: 31 August 2020 in Applied Sciences
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Mandibular reconstruction is a complicated task because of the complex nature of the regional anatomy. Computer-assisted tools are a promising means of improving the precision and safety of such complex surgeries. The digital techniques utilized in the reconstruction of mandibular defects based on medical data, computer-aided-design approaches, and three-dimensional (3D) printing are widely used to improve the patient’s aesthetic appearance and function, as well as the accuracy and quality of diagnosis, and surgical outcomes. Nevertheless, to ensure an acceptable aesthetical appearance and functional outcomes, the design must be based on proper anatomical reconstruction, mostly done in a virtual environment by skilled design engineers. Mirroring is one of the widely used techniques in the surgical navigation and reconstruction of mandibular defects. However, there are some discrepancies and mismatches in the mirrored anatomical models. Hence, in order to overcome these limitations in the mirroring technique, a novel approach called the cavity-filled technique was introduced. The objective of this study was to compare the accuracy of the newly recommended cavity-filled technique with the widely used mirror reconstruction technique in restoring mandibular defects. A prominent 3D comparison technique was employed in this work, where the resected and the reconstructed mandibles were superimposed to quantify the accuracy of the two techniques. From the analysis, it can be inferred that the cavity-filled technique with a root-mean-square value of 1.1019 mm produced better accuracy in contrast to the mirroring approach, which resulted in an error of 1.2683 mm. Consequently, by using the proposed cavity-filled design, the discrepancy between the reconstruction plate and the bone contour was mitigated. This method, owing to its high precision, can decrease the number of adjustments and the time of surgery, as well as ensure a quick recovery time with better implant tissue in-growth.

ACS Style

Khaja Moiduddin; Syed Hammad Mian; Wadea Ameen; Mohammed Alkindi; Sundar Ramalingam; Osama Alghamdi. Patient-Specific Surgical Implant Using Cavity-Filled Approach for Precise and Functional Mandible Reconstruction. Applied Sciences 2020, 10, 6030 .

AMA Style

Khaja Moiduddin, Syed Hammad Mian, Wadea Ameen, Mohammed Alkindi, Sundar Ramalingam, Osama Alghamdi. Patient-Specific Surgical Implant Using Cavity-Filled Approach for Precise and Functional Mandible Reconstruction. Applied Sciences. 2020; 10 (17):6030.

Chicago/Turabian Style

Khaja Moiduddin; Syed Hammad Mian; Wadea Ameen; Mohammed Alkindi; Sundar Ramalingam; Osama Alghamdi. 2020. "Patient-Specific Surgical Implant Using Cavity-Filled Approach for Precise and Functional Mandible Reconstruction." Applied Sciences 10, no. 17: 6030.

Journal article
Published: 29 July 2020 in Sustainability
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The emergence of Industry 4.0, also referred to as the fourth industrial revolution, has entirely transformed how the industry or business functions and evolves. It can be attributed to its broadening focus on automation, decentralization, system integration, cyber-physical systems, etc. Its implementation promises numerous benefits in terms of higher productivity, greater volatility, better control and streamlining of processes, accelerated enterprise growth, sustainable development, etc. Despite the worldwide recognition and realization of Industry 4.0, its holistic adoption is constrained by the requirements of specific skills among the workforce. The personnel are expected to acquire adaptive thinking, cognitive and computational skills, predominantly in the area of information technology, data analytics, etc. Thus, the universities that laid the foundation for future talents or trends in society have to adapt and modernize the existing programs, facilities, and infrastructure. This reshaping of higher education in consonance with the vision of Industry 4.0 possesses its opportunities and challenges. There are, of course, a multitude of factors involved and they need a reasonable assessment to strategically plan this metamorphosis. Therefore, this work aims to explore and analyze the different factors that influence the progression and enactment of Industry 4.0 in universities for sustainable education. For this purpose, a systematic approach based on a questionnaire as well as a SWOT (strengths (S), weaknesses (W), opportunities (O), and threats (T)) integrated with the analytic hierarchy process (AHP) is adopted. The questionnaires are administered to university employees and students (or stakeholders) to assess their viewpoint, as well as to estimate the priority values for individual factors to be included in SWOT. The AHP is implemented to quantify the different factors in terms of weights using a pairwise comparison matrix. Finally, the SWOT matrix is established depending on the questionnaire assessment and the AHP weights to figure out stakeholders’ perspectives, in addition to the needed strategic scheme. The SWOT implementation of this research proposes an aggressive approach for universities, where they must make full use of their strengths to take advantage of the emerging opportunities in Industry 4.0. The results also indicate that there are fundamental requirements for universities in Industry 4.0, including effective financial planning, skilled staff, increased industrial partnerships, advanced infrastructure, revised curricula, and insightful workshops. This investigation undoubtedly underlines the importance of practical expertise and the implementation of digital technologies at the university level to empower novices with the requisite skills and a competitive advantage for Industry 4.0.

ACS Style

Syed Hammad Mian; Bashir Salah; Wadea Ameen; Khaja Moiduddin; Hisham Alkhalefah. Adapting Universities for Sustainability Education in Industry 4.0: Channel of Challenges and Opportunities. Sustainability 2020, 12, 6100 .

AMA Style

Syed Hammad Mian, Bashir Salah, Wadea Ameen, Khaja Moiduddin, Hisham Alkhalefah. Adapting Universities for Sustainability Education in Industry 4.0: Channel of Challenges and Opportunities. Sustainability. 2020; 12 (15):6100.

Chicago/Turabian Style

Syed Hammad Mian; Bashir Salah; Wadea Ameen; Khaja Moiduddin; Hisham Alkhalefah. 2020. "Adapting Universities for Sustainability Education in Industry 4.0: Channel of Challenges and Opportunities." Sustainability 12, no. 15: 6100.

Journal article
Published: 28 July 2020 in Optics & Laser Technology
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The process enhancement plays a vital role in the modern machining techniques during machining of newer materials such as titanium alloys. In the present work, a research endeavor was made to examine the effects of process parameters in laser beam machining process while drilling holes over Titanium (Ti-6Al-4V) alloy under Taguchi approach of experiments. Nozzle distance, power, focal length and gas pressure were chosen as the input process parameters to assess the dimensional accuracy quality measures such as roundness and ovality in laser beam machining process. It was found that power has the most significant impact on determining the dimensional accuracy. 1.2 mm (ND), 2 mm (L), 4 bar (GP) and 2 kW (J) has been chosen as optimal process parameters combination for obtaining better dimensional accuracy among the selected process parameters. It was also observed that the machinability could be highly influenced with lower peak power.

ACS Style

T. Muthuramalingam; Khaja Moiduddin; Ravi Akash; Shravan Krishnan; Syed Hammad Mian; Wadea Ameen; Hisham Alkhalefah. Influence of process parameters on dimensional accuracy of machined Titanium (Ti-6Al-4V) alloy in Laser Beam Machining Process. Optics & Laser Technology 2020, 132, 106494 .

AMA Style

T. Muthuramalingam, Khaja Moiduddin, Ravi Akash, Shravan Krishnan, Syed Hammad Mian, Wadea Ameen, Hisham Alkhalefah. Influence of process parameters on dimensional accuracy of machined Titanium (Ti-6Al-4V) alloy in Laser Beam Machining Process. Optics & Laser Technology. 2020; 132 ():106494.

Chicago/Turabian Style

T. Muthuramalingam; Khaja Moiduddin; Ravi Akash; Shravan Krishnan; Syed Hammad Mian; Wadea Ameen; Hisham Alkhalefah. 2020. "Influence of process parameters on dimensional accuracy of machined Titanium (Ti-6Al-4V) alloy in Laser Beam Machining Process." Optics & Laser Technology 132, no. : 106494.

Journal article
Published: 01 July 2020 in Sensors
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A real-time roundabout detection and navigation system for smart vehicles and cities using laser simulator–fuzzy logic algorithms and sensor fusion in a road environment is presented in this paper. A wheeled mobile robot (WMR) is supposed to navigate autonomously on the road in real-time and reach a predefined goal while discovering and detecting the road roundabout. A complete modeling and path planning of the road’s roundabout intersection was derived to enable the WMR to navigate autonomously in indoor and outdoor terrains. A new algorithm, called Laser Simulator, has been introduced to detect various entities in a road roundabout setting, which is later integrated with fuzzy logic algorithm for making the right decision about the existence of the roundabout. The sensor fusion process involving the use of a Wi-Fi camera, laser range finder, and odometry was implemented to generate the robot’s path planning and localization within the road environment. The local maps were built using the extracted data from the camera and laser range finder to estimate the road parameters such as road width, side curbs, and roundabout center, all in two-dimensional space. The path generation algorithm was fully derived within the local maps and tested with a WMR platform in real-time.

ACS Style

Mohammed A. H. Ali; Musa Mailah; Waheb A. Jabbar; Khaja Moiduddin; Wadea Ameen; Hisham Alkhalefah. Autonomous Road Roundabout Detection and Navigation System for Smart Vehicles and Cities Using Laser Simulator–Fuzzy Logic Algorithms and Sensor Fusion. Sensors 2020, 20, 3694 .

AMA Style

Mohammed A. H. Ali, Musa Mailah, Waheb A. Jabbar, Khaja Moiduddin, Wadea Ameen, Hisham Alkhalefah. Autonomous Road Roundabout Detection and Navigation System for Smart Vehicles and Cities Using Laser Simulator–Fuzzy Logic Algorithms and Sensor Fusion. Sensors. 2020; 20 (13):3694.

Chicago/Turabian Style

Mohammed A. H. Ali; Musa Mailah; Waheb A. Jabbar; Khaja Moiduddin; Wadea Ameen; Hisham Alkhalefah. 2020. "Autonomous Road Roundabout Detection and Navigation System for Smart Vehicles and Cities Using Laser Simulator–Fuzzy Logic Algorithms and Sensor Fusion." Sensors 20, no. 13: 3694.

Journal article
Published: 22 November 2019 in Metals
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Reconstruction of zygomatic complex defects is a surgical challenge, owing to the accurate restoration of structural symmetry as well as facial projection. Generally, there are many available techniques for zygomatic reconstruction, but they hardly achieve aesthetic and functional properties. To our knowledge, there is no such study on zygomatic titanium bone reconstruction, which involves the complete steps from patient computed tomography scan to the fabrication of titanium zygomatic implant and evaluation of implant accuracy. The objective of this study is to propose an integrated system methodology for the reconstruction of complex zygomatic bony defects using titanium comprising several steps, right from the patient scan to implant fabrication while maintaining proper aesthetic and facial symmetry. The integrated system methodology involves computer-assisted implant design based on the patient computed tomography data, the implant fitting accuracy using three-dimensional comparison techniques, finite element analysis to investigate the biomechanical behavior under loading conditions, and finally titanium fabrication of the zygomatic implant using state-of-the-art electron beam melting technology. The resulting titanium implant has a superior aesthetic appearance and preferable biocompatibility. The customized mirrored implant accurately fit on the defective area and restored the tumor region with inconsequential inconsistency. Moreover, the outcome from the two-dimensional analysis provided a good accuracy within 2 mm as established through physical prototyping. Thus, the designed implant produced faultless fitting, favorable symmetry, and satisfying aesthetics. The simulation results also demonstrated the load resistant ability of the implant with max stress within 1.76 MPa. Certainly, the mirrored and electron beam melted titanium implant can be considered as the practical alternative for a bone substitute of complex zygomatic reconstruction.

ACS Style

Khaja Moiduddin; Syed Hammad Mian; Usama Umer; Naveed Ahmed; Hisham Alkhalefah; Wadea Ameen. Reconstruction of Complex Zygomatic Bone Defects Using Mirroring Coupled with EBM Fabrication of Titanium Implant. Metals 2019, 9, 1250 .

AMA Style

Khaja Moiduddin, Syed Hammad Mian, Usama Umer, Naveed Ahmed, Hisham Alkhalefah, Wadea Ameen. Reconstruction of Complex Zygomatic Bone Defects Using Mirroring Coupled with EBM Fabrication of Titanium Implant. Metals. 2019; 9 (12):1250.

Chicago/Turabian Style

Khaja Moiduddin; Syed Hammad Mian; Usama Umer; Naveed Ahmed; Hisham Alkhalefah; Wadea Ameen. 2019. "Reconstruction of Complex Zygomatic Bone Defects Using Mirroring Coupled with EBM Fabrication of Titanium Implant." Metals 9, no. 12: 1250.

Journal article
Published: 11 November 2019 in Metals
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The addition of support structures is essential for the successful fabrication of overhang structures through additive manufacturing (AM). The support structures protect the overhang portion from distortions. They are fabricated with the functional parts and are removed later after the fabrication of the AM part. While structures bearing insufficient support result in defective overhangs, structures with excessive support result in higher material consumption, time and higher post-processing costs. The objective of this study is to investigate the effects of design and process parameters of support structures on support removability during the electron beam melting (EBM)-based additive manufacturing of the Ti6Al4V overhang part. The support design parameters include tooth parameters, no support offset, fragmentation parameters and perforation parameters. The EBM process parameters consist of beam current, beam scan speed and beam focus offset. The results show that both support design and process parameters have a significant effect on support removability. In addition, with the appropriate selection of design and process parameters, it is possible to significantly reduce the support removal time and protect the surface quality of the part.

ACS Style

Wadea Ameen; Muneer Khan Mohammed; Abdulrahman Al-Ahmari. Evaluation of Support Structure Removability for Additively Manufactured Ti6Al4V Overhangs via Electron Beam Melting. Metals 2019, 9, 1211 .

AMA Style

Wadea Ameen, Muneer Khan Mohammed, Abdulrahman Al-Ahmari. Evaluation of Support Structure Removability for Additively Manufactured Ti6Al4V Overhangs via Electron Beam Melting. Metals. 2019; 9 (11):1211.

Chicago/Turabian Style

Wadea Ameen; Muneer Khan Mohammed; Abdulrahman Al-Ahmari. 2019. "Evaluation of Support Structure Removability for Additively Manufactured Ti6Al4V Overhangs via Electron Beam Melting." Metals 9, no. 11: 1211.

Journal article
Published: 22 July 2019 in Metals
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Electron beam melting (EBM) technology is a novel additive manufacturing (AM) technique, which uses computer controlled electron beams to create fully dense three-dimensional objects from metal powder. It gives the ability to produce any complex parts directly from a computer aided design (CAD) model without tools and dies, and with variety of materials. However, it is reported that EBM has limitations in building overhang structures, due to the poor thermal conductivity for the sintered powder particles under overhang surfaces. In the current study, 2D thermo-mechanical finite element models (FEM) are developed to predict the stresses and deformation associated with fabrication of overhang structures by EBM for Ti-6Al-4V alloy. Different support structure geometries are modeled and evaluated. Finally, the numerical results are validated by experimental work.

ACS Style

Usama Umer; Wadea Ameen; Mustufa Haider Abidi; Khaja Moiduddin; Hisham Alkhalefah; Mohammed Alkahtani; Abdulrahman Al-Ahmari. Modeling the Effect of Different Support Structures in Electron Beam Melting of Titanium Alloy Using Finite Element Models. Metals 2019, 9, 806 .

AMA Style

Usama Umer, Wadea Ameen, Mustufa Haider Abidi, Khaja Moiduddin, Hisham Alkhalefah, Mohammed Alkahtani, Abdulrahman Al-Ahmari. Modeling the Effect of Different Support Structures in Electron Beam Melting of Titanium Alloy Using Finite Element Models. Metals. 2019; 9 (7):806.

Chicago/Turabian Style

Usama Umer; Wadea Ameen; Mustufa Haider Abidi; Khaja Moiduddin; Hisham Alkhalefah; Mohammed Alkahtani; Abdulrahman Al-Ahmari. 2019. "Modeling the Effect of Different Support Structures in Electron Beam Melting of Titanium Alloy Using Finite Element Models." Metals 9, no. 7: 806.

Original article
Published: 28 June 2019 in The International Journal of Advanced Manufacturing Technology
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The aim of this study is to identify the limitations of self-supporting structures and evaluate the deformations associated with overhang structures fabricated without support structures. To achieve these objectives, a series of experiments involving different overhang geometries were designed, fabricated, and evaluated. The formation of defects during the fabrication of overhanging structures is detailed, and the self-supporting limits for different overhangs are established. A segmentation strategy for the support structure addition is proposed and evaluated in different configurations for ledge overhangs to reduce the amount of support structures without affecting the overhang accuracy. Based on the inferences of this study, design rules are proposed for producing overhang structures through electron beam melting. The results identified the self-supporting limits for different overhang geometries. In addition, the proposed segmentation strategy for support generation in ledge overhangs resulted in reduction of support structure materials and post-processing time without any effect on the quality of the fabricated overhang.

ACS Style

Wadea Ameen; Abdulrahman Al-Ahmari; Muneer Khan Mohammed. Self-supporting overhang structures produced by additive manufacturing through electron beam melting. The International Journal of Advanced Manufacturing Technology 2019, 104, 2215 -2232.

AMA Style

Wadea Ameen, Abdulrahman Al-Ahmari, Muneer Khan Mohammed. Self-supporting overhang structures produced by additive manufacturing through electron beam melting. The International Journal of Advanced Manufacturing Technology. 2019; 104 (5-8):2215-2232.

Chicago/Turabian Style

Wadea Ameen; Abdulrahman Al-Ahmari; Muneer Khan Mohammed. 2019. "Self-supporting overhang structures produced by additive manufacturing through electron beam melting." The International Journal of Advanced Manufacturing Technology 104, no. 5-8: 2215-2232.

Journal article
Published: 01 January 2019 in International Journal of Materials and Product Technology
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ACS Style

Wadea Ameen; Syed Hammad Mian; Abdulrahman Al Ahmari; Mohammed Ashfaq. Evaluation of additive manufacturing technologies for dimensional and geometric accuracy. International Journal of Materials and Product Technology 2019, 58, 129 .

AMA Style

Wadea Ameen, Syed Hammad Mian, Abdulrahman Al Ahmari, Mohammed Ashfaq. Evaluation of additive manufacturing technologies for dimensional and geometric accuracy. International Journal of Materials and Product Technology. 2019; 58 (2/3):129.

Chicago/Turabian Style

Wadea Ameen; Syed Hammad Mian; Abdulrahman Al Ahmari; Mohammed Ashfaq. 2019. "Evaluation of additive manufacturing technologies for dimensional and geometric accuracy." International Journal of Materials and Product Technology 58, no. 2/3: 129.

Journal article
Published: 28 September 2018 in Rapid Prototyping Journal
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Purpose Hybrid manufacturing technologies combining individual processes can be recognized as one of the most cogent developments in recent times. As a result of integrating additive, subtractive and inspection processes within a single system, the relative benefits of each process can be exploited. This collaboration uses the strength of the individual processes, while decreasing the shortcomings and broadening the application areas. Notwithstanding its numerous advantages, the implementation of hybrid technology is typically affected by the limited process planning methods. The process planning methods proficient at effectively using manufacturing sources for hybridization are notably restrictive. Hence, this paper aims to propose a computer-aided process planning system for hybrid additive, subtractive and inspection processes. A dynamic process plan has been developed, wherein an online process control with intelligent and autonomous characteristics, as well as the feedback from the inspection, is utilized. Design/methodology/approach In this research, a computer-aided process planning system for hybrid additive, subtractive and inspection process has been proposed. A framework based on the integration of three phases has been designed and implemented. The first phase has been developed for the generation of alternative plans or different scenarios depending on machining parameters, the amount of material to be added and removed in additive and subtractive manufacturing, etc. The primary objective in this phase has been to conduct set-up planning, process selection, process sequencing, selection of machine parameters, etc. The second phase is aimed at the identification of the optimum scenario or plan. Findings To accomplish this goal, economic models for additive and subtractive manufacturing were used. The objective of the third phase was to generate a dynamic process plan depending on the inspection feedback. For this purpose, a multi-agent system has been used. The multi-agent system has been used to achieve intelligence and autonomy of different phases. Practical implications A case study has been developed to test and validate the proposed algorithm and establish the performance of the proposed system. Originality/value The major contribution of this work is the novel dynamic computer-aided process planning system for the hybrid process. This hybrid process is not limited by the shortcomings of the constituent processes in terms of tool accessibility and support volume. It has been established that the hybrid process together with an appropriate computer-aided process plan provides an effective solution to accurately fabricate a variety of complex parts.

ACS Style

Osama Abdulhameed; Abdurahman Mushabab Al-Ahmari; Wadea Ameen; Syed Hammad Mian. Novel dynamic CAPP system for hybrid additive–subtractive–inspection process. Rapid Prototyping Journal 2018, 24, 988 -1002.

AMA Style

Osama Abdulhameed, Abdurahman Mushabab Al-Ahmari, Wadea Ameen, Syed Hammad Mian. Novel dynamic CAPP system for hybrid additive–subtractive–inspection process. Rapid Prototyping Journal. 2018; 24 (6):988-1002.

Chicago/Turabian Style

Osama Abdulhameed; Abdurahman Mushabab Al-Ahmari; Wadea Ameen; Syed Hammad Mian. 2018. "Novel dynamic CAPP system for hybrid additive–subtractive–inspection process." Rapid Prototyping Journal 24, no. 6: 988-1002.

Journal article
Published: 21 September 2018 in Advances in Production Engineering & Management
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ACS Style

W. Ameen; A. Al-Ahmari; M.K. Mohammed; O. AbdulHameed; U. Umer; K. Moiduddin. Design, finite element analysis (FEA), and fabrication of custom titanium alloy cranial implant using electron beam melting additive manufacturing. Advances in Production Engineering & Management 2018, 13, 267 -278.

AMA Style

W. Ameen, A. Al-Ahmari, M.K. Mohammed, O. AbdulHameed, U. Umer, K. Moiduddin. Design, finite element analysis (FEA), and fabrication of custom titanium alloy cranial implant using electron beam melting additive manufacturing. Advances in Production Engineering & Management. 2018; 13 (3):267-278.

Chicago/Turabian Style

W. Ameen; A. Al-Ahmari; M.K. Mohammed; O. AbdulHameed; U. Umer; K. Moiduddin. 2018. "Design, finite element analysis (FEA), and fabrication of custom titanium alloy cranial implant using electron beam melting additive manufacturing." Advances in Production Engineering & Management 13, no. 3: 267-278.

Review
Published: 02 July 2018 in Virtual and Physical Prototyping
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The aim of this paper is to present an overview of published research in selective laser sintering/melting (SLS/M), by using bibliometric indicators. Bibliometrics is the quantitative statistical analysis of written publications, such as articles or books. It is useful for displaying and classifying information according to selected variables, such as authors, journals, citations, countries, and institutions. This type of review provides a clear picture of research in a targeted area, such as the most cited research, author with most publications, journal with most published papers, and universities and countries producing the largest amount of research in the target area. The Web of Science database was used to collect data on the topic of interest. The results reveal that the Rapid Prototyping journal is the most productive journal in this field, where the Huazhong University Science Technology is the most effective institution. Also China is the most productive country, whereas USA is the most influential country.

ACS Style

Wadea Ameen; Atef M. Ghaleb; Moath Alatefi; Hisham Alkhalefah; Abdulrahman AlAhmari. An overview of selective laser sintering and melting research using bibliometric indicators. Virtual and Physical Prototyping 2018, 13, 282 -291.

AMA Style

Wadea Ameen, Atef M. Ghaleb, Moath Alatefi, Hisham Alkhalefah, Abdulrahman AlAhmari. An overview of selective laser sintering and melting research using bibliometric indicators. Virtual and Physical Prototyping. 2018; 13 (4):282-291.

Chicago/Turabian Style

Wadea Ameen; Atef M. Ghaleb; Moath Alatefi; Hisham Alkhalefah; Abdulrahman AlAhmari. 2018. "An overview of selective laser sintering and melting research using bibliometric indicators." Virtual and Physical Prototyping 13, no. 4: 282-291.

Journal article
Published: 01 July 2018 in International Journal of Industrial Ergonomics
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Assembly is an important aspect of the manufacturing process. Proper assembly training plays a vital role for efficient operations. Therefore, this paper suggests a new assembly training approach based on 3D printing technology. The proposed approach is compared to existing assembly training methods including conventional drawing (CD) and virtual reality (VR). Different size scales of product are considered to evaluate and validate the suggested 3D printing approach. The training performance is evaluated based on completion time of assembly task, number of assembly errors, number of frustration points during the task, and completion percentage. The experiments have been conducted on 25 participants using the three assembly training approaches. The obtained results show that the 3D model performed better than the other two conventional methods. The results also illustrate that there is no significant effect from the 3D model scale variation on the assembly training performance.

ACS Style

Abdulrahman Al-Ahmari; Wadea Ameen; Mustufa Haider Abidi; Syed Hammad Mian. Evaluation of 3D printing approach for manual assembly training. International Journal of Industrial Ergonomics 2018, 66, 57 -62.

AMA Style

Abdulrahman Al-Ahmari, Wadea Ameen, Mustufa Haider Abidi, Syed Hammad Mian. Evaluation of 3D printing approach for manual assembly training. International Journal of Industrial Ergonomics. 2018; 66 ():57-62.

Chicago/Turabian Style

Abdulrahman Al-Ahmari; Wadea Ameen; Mustufa Haider Abidi; Syed Hammad Mian. 2018. "Evaluation of 3D printing approach for manual assembly training." International Journal of Industrial Ergonomics 66, no. : 57-62.

Journal article
Published: 01 July 2018 in Journal of King Saud University - Engineering Sciences
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The buffer allocation problem concerning the size and location of storage between the stages of a flow line is a critical research area in the design of production lines. In this study, a production system consisting of two unreliable stages and a buffer between them is considered; the first stage incorporates two identical machines in parallel and the second stage consists of a single machine. A simulation model is designed and used to evaluate the effect of the buffer capacity and the repair rates of machines on production line efficiency. The results revealed the capacity of buffer that yields the maximum production line efficiency with various repair rate values.

ACS Style

Wadea Ameen; Mohammed Alkahtani; Muneer Khan Mohammed; Osama AbdulHameed; Abdulaziz Mohammed El-Tamimi. Investigation of the effect of buffer storage capacity and repair rate on production line efficiency. Journal of King Saud University - Engineering Sciences 2018, 30, 243 -249.

AMA Style

Wadea Ameen, Mohammed Alkahtani, Muneer Khan Mohammed, Osama AbdulHameed, Abdulaziz Mohammed El-Tamimi. Investigation of the effect of buffer storage capacity and repair rate on production line efficiency. Journal of King Saud University - Engineering Sciences. 2018; 30 (3):243-249.

Chicago/Turabian Style

Wadea Ameen; Mohammed Alkahtani; Muneer Khan Mohammed; Osama AbdulHameed; Abdulaziz Mohammed El-Tamimi. 2018. "Investigation of the effect of buffer storage capacity and repair rate on production line efficiency." Journal of King Saud University - Engineering Sciences 30, no. 3: 243-249.

Journal article
Published: 30 May 2018 in Metals
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This study aims to investigate the manufacturability of overhang round holes with and without support. The experiments were conducted by electron beam melting (EBM) using a Ti6Al4V powder. A large number of overhanging holes with and without support were fabricated and evaluated. The geometrical accuracy, mechanical properties, and microstructures were utilized as a measure of the process performance. It was demonstrated that overhanging features can be built successfully without support up to a certain dimension (or threshold value). Beyond that value, a minimal support structure can be employed to achieve the most suitable trade-off between production time, cost, and accuracy.

ACS Style

Wadea Ameen; Abdulrahman Al-Ahmari; Muneer Khan Mohammed; Syed Hammad Mian. Manufacturability of Overhanging Holes Using Electron Beam Melting. Metals 2018, 8, 397 .

AMA Style

Wadea Ameen, Abdulrahman Al-Ahmari, Muneer Khan Mohammed, Syed Hammad Mian. Manufacturability of Overhanging Holes Using Electron Beam Melting. Metals. 2018; 8 (6):397.

Chicago/Turabian Style

Wadea Ameen; Abdulrahman Al-Ahmari; Muneer Khan Mohammed; Syed Hammad Mian. 2018. "Manufacturability of Overhanging Holes Using Electron Beam Melting." Metals 8, no. 6: 397.

Journal article
Published: 31 January 2018 in Applied Sciences
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The process of generating a computerized geometric model for an existing part is known as Reverse Engineering (RE). It is a very useful technique in product development and plays a significant role in automotive, aerospace, and medical industries. In fact, it has been getting remarkable attention in manufacturing industries owing to its advanced data acquisition technologies. The process of RE is based on two primary steps: data acquisition (also known as scanning) and data processing. To facilitate point data acquisition, a variety of scanning systems is available with different capabilities and limitations. Although the optical control of 3D scanners is fully developed, still several factors can affect the quality of the scanned data. As a result, the proper selection of scanning parameters, such as resolution, laser power, shutter time, etc., becomes very crucial. This kind of investigation can be very helpful and provide its users with guidelines to identify the appropriate factors. Moreover, it is worth noting that no single system is ideal in all applications. Accordingly, this work has compared two portable (handheld) systems based on laser scanning and white light optical scanning for automotive applications. A car door containing a free-form surface has been used to achieve the above-mentioned goal. The design of experiments has been employed to determine the effects of different scanning parameters and optimize them. The capabilities and limitations have been identified by comparing the two scanners in terms of accuracy, scanning time, triangle numbers, ease of use, and portability. Then, the relationships between the system capabilities and the application requirements have been established. The results revealed that the laser scanner performed better than the white light scanner in terms of accuracy, while the white light scanner performed better in terms of acquisition speed and triangle numbers.

ACS Style

Wadea Ameen; Abdulrahman M. Al-Ahmari; Syed Hammad Mian. Evaluation of Handheld Scanners for Automotive Applications. Applied Sciences 2018, 8, 217 .

AMA Style

Wadea Ameen, Abdulrahman M. Al-Ahmari, Syed Hammad Mian. Evaluation of Handheld Scanners for Automotive Applications. Applied Sciences. 2018; 8 (2):217.

Chicago/Turabian Style

Wadea Ameen; Abdulrahman M. Al-Ahmari; Syed Hammad Mian. 2018. "Evaluation of Handheld Scanners for Automotive Applications." Applied Sciences 8, no. 2: 217.

Journal article
Published: 01 September 2017 in Electronic Journal of Biotechnology
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Background: Reconstruction of customized cranial implants with a mesh structure using computer-assisted design and additive manufacturing improves the implant design, surgical planning, defect evaluation, implant-tissue interaction and surgeon's accuracy. The objective of this study is to design, develop and fabricate cranial implant with mechanical properties closer to that of bone and drastically decreases the implant failure and to improve the esthetic outcome in cranial surgery with precision fitting for a better quality of life. A customized cranial mesh implant is designed digitally, based on the Digital Imaging and Communication in Medicine files and fabricated using state of the Art-Electron Beam Melting an Additive Manufacturing technology. The EBM produced titanium implant was evaluated based on their mechanical strength and structural characterization. Results: The result shows, the produced mesh implants have a high permeability of bone ingrowth with its reduced weight and modulus of elasticity closer to that the natural bone thus reducing the stress shielding effect. Scanning electron microscope and micro-computed tomography (CT) scanning confirms, that the produced cranial implant has a highly regular pattern of the porous structure with interconnected channels without any internal defect and voids. Conclusions: The study reveals that the use of mesh implants in cranial reconstruction satisfies the need of lighter implants with an adequate mechanical strength, thus restoring better functionality and esthetic outcomes for the patients

ACS Style

Khaja Moiduddin; Saied Darwish; Abdulrahman Al-Ahmari; Sherif ElWatidy; Ashfaq Mohammad; Wadea Ameen. Structural and mechanical characterization of custom design cranial implant created using additive manufacturing. Electronic Journal of Biotechnology 2017, 29, 22 -31.

AMA Style

Khaja Moiduddin, Saied Darwish, Abdulrahman Al-Ahmari, Sherif ElWatidy, Ashfaq Mohammad, Wadea Ameen. Structural and mechanical characterization of custom design cranial implant created using additive manufacturing. Electronic Journal of Biotechnology. 2017; 29 ():22-31.

Chicago/Turabian Style

Khaja Moiduddin; Saied Darwish; Abdulrahman Al-Ahmari; Sherif ElWatidy; Ashfaq Mohammad; Wadea Ameen. 2017. "Structural and mechanical characterization of custom design cranial implant created using additive manufacturing." Electronic Journal of Biotechnology 29, no. : 22-31.