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Ossama D.

Self-employed / FE simulation and design

Denzlingen, Germany

Experience

Jan 2016 - Present
10 years
Denzlingen, Germany

Self-employed / FE simulation and design

Various companies

  • Designing and developing charging inlets for megawatt charging systems
  • Developing strategies for AI applications in mechanical engineering
  • Creating concepts for inductive charging systems for self-driving vehicles in industrial settings
  • Drafting concepts for electronically controlled safety brakes for elevators
  • Designing power generators with and without iron cores (power under 1 kV)
  • Developing labeling solutions for plastic and stainless steel components
  • Designing various mounting brackets following EHEDG guidelines
  • Requirements management using JAMA
  • Simulating strength behavior of wastewater treatment plants
  • FE optimization simulation of device behavior under vibration loadings with ANSYS
  • Maintaining bills of materials and databases
  • Developing various opto-mechanical systems for distance measurement and safety light curtains
  • Rapid prototyping like 3D printing, SLS, liquid silicone, STL
  • Designing modules and connection methods to integrate power supply and data management units on PCBs
  • Designing shielding elements for industrial equipment
  • Implementing design solutions for connecting PCBs to each other or to connectors and cables
  • Designing busbars to meet ESD requirements
  • Designing fasteners
  • Designing fasteners from V4A steels with clinch, crimp, and/or riveting options for use in hygienic equipment
  • Developing 2K injection molded parts
  • Designing stainless steel V4A cable glands for hygienic equipment
  • Designing devices with optical and electronic modules
  • Conducting qualification tests (temperature cycling, leak tests, climate tests, etc.)
  • Performing process and design FMEA
  • Development following agile processes
  • Material-specific design for chemical resistance (cleaning and disinfecting agents)
  • Optimizing injection molded parts for ultrasonic and laser welding
  • Developing injection molded parts and compressed elastomers
  • Studying the impact of marking methods (laser engraving and electrolytic marking) on part resistance to cleaning and disinfecting agents
  • Corrosion evaluation and testing of stainless steel parts
  • Machining-oriented part design from welded semi-finished products (V4A stainless steels)
  • Designing metallic parts for wireless power transmission devices (CAD Creo Parametric)
  • Creating drawings and models for clients
  • FE analysis of elastomer seal behavior including installation (CAE ANSYS)
  • Design and construction for bonding glass to stainless steel V4A per EHEDG guidelines
  • Implementing design solutions for joining similar and dissimilar materials (adhesive bonding, welding, snap hooks) (CAD: Creo Direct Modeling and SolidWorks)
  • Designing equipment for the pharmaceutical and food industries from FDA-approved materials and per EHEDG guidelines (CAD: Creo Direct Modeling and SolidWorks)
  • FE analysis of temperature effects on plastic assemblies (CAE ANSYS)
  • Enhancing a tool for FE analysis of additive manufacturing (laser sintering) (CAE CalculiX)
  • CAD & CAE engineering consulting and services
  • Improving FE systems for strength analysis and topology optimization
  • Developing and implementing an indicator lamp made of electronic, optical, and mechanical components for safety modules in special machinery (injection molded parts) (CAD: Creo Direct Modeling)
  • FE simulation to study assembly tightness and optimize seals (CAE ANSYS)
May 2013 - Dec 2015
2 years 8 months
Freiburg im Breisgau, Germany

Research associate

Fraunhofer Institute for Mechanics of Materials IWM

  • Studying metallurgy and strength of welds regarding residual stress formation
  • Experimental work to generate material data for welding simulation (thermo-mechanical, physical and metallurgical data)
  • Developing material models for welding simulation
  • Performing numerical analyses of the welding process as single-step and full production chain
  • Project management and coordination with other research institutes
  • Optimizing welding processes to reduce distortion of parts, e.g., aluminum housings with active water cooling
  • Representing the group in committees, conferences, and to project partners
  • Designing test specimens to generate material data for crash simulations, e.g., from aluminum profiles and sheets
Jan 2009 - Apr 2013
4 years 4 months
Cottbus, Germany

Research associate, Chair of Joining and Welding Technology

Brandenburg University of Technology Cottbus

  • Research on thermo-metallurgical and mechanical simulation (physical and numerical) of local part properties. Funded project by the state of Brandenburg “Compression Technologies and Materials”
  • Conducting material characterization tests under manufacturing conditions for various materials and welding methods like high-strength steels, creep-resistant steels, aluminum alloys, ceramics, etc.
  • Developing methods to test refractory ceramics
  • Developing a method to study hydrogen effects on welds, especially for laser beam welding
  • Writing project proposals (DFG and DVS/FoStA)
  • PhD on “Physical welding simulation of the cold crack susceptibility” (Dr.-Ing., summa cum laude)
  • Developing a welding simulation tool during the PhD to assess cold crack risk in welds precisely.
Apr 2008 - Dec 2008
9 months
Sindelfingen, Germany

Development engineer / designer

Autokabel Management GmbH

  • Packaging space studies, examining engine bays of cars for new or modified units (CAD: CATIA V5)
  • Project coordination and management, project development with other automotive suppliers
  • Designing components for the start-stop vehicle system, e.g., copper alloy busbars, steel sheet brackets, connectors for electrical/electronic units, cable lugs, etc.
  • Routing car cables in CATIA V5 (design and development of aluminum vehicle cables to reduce weight)
  • Creating prototypes (STL parts) and initial sample components
  • Client support
Aug 2007 - Mar 2008
8 months
Fellbach, Germany

Development engineer

Encontec GmbH

  • Developing and designing various vehicle components (CAD: Inventor and ProE)
  • Developing a new generation of the exhaust aftertreatment conveyance module for diesel vehicles for Bosch GmbH
  • Conducting tolerance analyses for various assemblies in automotive and plant engineering
  • Client support
Feb 2007 - Aug 2007
7 months
Waiblingen, Germany

Thesis

Robert Bosch GmbH

  • Topic: “Development and implementation of a conveyance module assembly for exhaust aftertreatment in diesel vehicles regarding product quality”
  • Designing a mini membrane pump from fiber-reinforced plastic (CAD: ProE)
  • Developing an electric drive to control flow direction (CAE: Maxwell 2D)
  • Building prototypes and testing functionality
  • Liaising with suppliers
  • The developed conveyance unit was patented at Bosch
Oct 2006 - Jan 2007
4 months
Waiblingen, Germany

Internship

Robert Bosch GmbH

  • Coordinating and building prototypes
  • Drafting and implementing design improvements
  • Liaising with suppliers
  • Working in the SE team
  • Maintaining bills of materials
Apr 1998 - Oct 2003
5 years 7 months
Latakia, Syrian Arab Republic

Development engineer

Syriatelekom

  • Service and commissioning of power conversion units and continuous power feeding systems
  • Writing specifications for power supply, power conversion, and safety systems
Oct 1992 - Oct 1997
5 years 1 month
Latakia, Syrian Arab Republic

Founder / designer

Small welding workshop

  • Designing and assembling mobile units (e.g., tractor trailers, water tanks, plows) for agriculture.

Summary

  • Construction, calculation, simulation, development, project management, testing, FMEA, plant engineering, vehicle technology, mechanical engineering, pressure vessel engineering, bodywork, assembly/joining technology, steel construction, research and teaching, materials engineering, welding technology, bonding, steel, plastics and composites
  • Inventor, CATIA V5, Creo, Creo Direct Modeling, SolidWorks, Fusion 360, ANSYS, ABAQUS
  • SYSWELD, Simufact, Linux and Windows.

Languages

Arabic
Native
German
Native
English
Advanced

Education

Jan 2009 - Jun 2014

BTU Cottbus-Senftenberg

Dr.-Ing. · Cottbus, Germany · summa cum laude

Oct 2003 - Jul 2007

TU Ilmenau

Dipl.-Ing. · Design engineering · Ilmenau, Germany

Oct 1992 - Oct 1997

Tichreen University

Bachelor · Production engineering · Latakia, Syrian Arab Republic

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