User:Ali.abdelrahman

Ali Abdelrahman is a Mechanical and Materials Engineering student in the co-op program at Western University (London, Ontario, Canada). His interests are materials, advanced manufacturing, and mechanical/product design, especially design for manufacturing and assembly (DFM/DFA), 3D printing, and taking hardware from prototype to production. He is interested in the FAST research group's work on distributed recycling and additive manufacturing (DRAM) and open-source hardware.

Western University, London, ON: Bachelor of Engineering Science in Mechanical and Materials Engineering (expected April 2028)

• Entrance Scholarship of Distinction
• Western Baja Racing Team (SAE)
• Relevant coursework: Mechanics & Properties of Materials, Engineering Design, Thermodynamics, Heat Transfer

MIT Sloan School of Management: Machine Learning in Business (6-week certificate course)

• Liquid-cooled 800 V power shelves for AI server racks: redesigned the cooling plate layout for easier manufacturing and assembly, cutting coolant leak points by 80% and assembly time by 40%; prototype brackets held to ±0.50 mm to fit the server rack. Aligned the design with partner rack and power electronics requirements, enabling 150 kW per shelf, and built test equipment that cut cooling system service time by 30%.
• Resolved a recurring manufacturing defect: traced a repeated sensor installation error to its root cause and engineered a wiring fix that reduced rework from 45 to 5 minutes per unit (89%), then standardized the fix across overseas manufacturing.
• Led a next-generation rack power distribution unit release (20,000+ units): took the product from engineering prototype to manufacturing-ready, owning prototyping, testing, parts lists and engineering drawings in Creo and Windchill; sourced UL-certified components, released parts into production systems, created customer wiring diagrams, coordinated the India manufacturing team, and led interns on prototype builds.
• Wiring harness DFA redesign: cut harness cost by 25% (about $100,000 in savings) by prototyping dozens of wiring routes and designing custom 3D-printed cable supports to replace cost-prohibitive off-the-shelf parts, minimizing copper use and simplifying assembly while meeting UL safety standards.
• Test equipment and validation: built a custom high-voltage (hipot) safety test fixture and validated units through electrical safety, load, and power-quality testing.

• Resolved hardware and connectivity issues for students and faculty using structured root-cause troubleshooting.

• Designed sheet metal body panels and designed and 3D-printed mounting tabs in SolidWorks, cutting weight 30% versus the previous design while fitting the chassis and cockpit using DFM strategies.
• Engineered seat mounting structures to meet SAE competition safety rules and driver load requirements, increasing seat stability; the team ranked first in Canada.

• Designed a linear-actuated elbow joint, optimizing linkage geometry for motion and load requirements, converting motor torque into linear actuation to simulate a human joint.
• Created detailed SolidWorks assemblies, applying DFM/DFA to improve manufacturability and assembly reliability.

• Designed and built a temperature-controlled apparatus to measure LED luminous efficiency as a function of temperature.
• Integrated thermocouples, photocells and NI DAQ hardware, and developed LabVIEW software to collect and visualize real-time data; the project placed in the top 3 of over 100 students.

• Built a full-stack workout planning web app (progressive web app deployed on Vercel with a Supabase backend). Live site: https://training-planner-pro.vercel.app

• CAD & product design: Creo, SolidWorks, Onshape, tolerance analysis, DFM/DFA, 3D modeling and assemblies, mechanical drawings
• Manufacturing & prototyping: prototype build and fabrication, fixture design, 3D printing (Bambu Lab, Prusa), CNC routing, lathe operation, part sourcing, assembly, drop testing
• PDM & documentation: BOM management, PDM Windchill, Oracle, Visio, work instructions, technical documentation
• Testing & validation: hipot, waveform and resistive-load testing, NI DAQ, LabVIEW, MATLAB, data analysis

English, Arabic (Egyptian)

aabde2@uwo.ca | LinkedIn