Shahmeer Baweja | Mechanical Engineer | Simulation

Featured Projects

Showcasing my mechanical engineering expertise

AI-Driven Surrogate Modeling for Multiaxial Creep (Argonne)

Developed an active-learning-driven Gaussian Process surrogate to accelerate high-fidelity CPFE predictions of creep rupture in Alloy 709 and LPBF 316H under multiaxial stress states using MOOSE + NEML.

MOOSE NEML CPFE Gaussian Process Active Learning

5× Cost Reduction

85% Error Drop

Automated Multi-Axial CPFE Simulations (Magnesium Alloys)

Ran hundreds of 3D CPFE simulations to study the coupled effects of texture, grain orientation, triaxiality, and strain rate on anisotropy, twinning activity, localization, and ductility in HCP metals.

Abaqus UMAT FORTRAN Neper Python HPC Automation

10× Faster Turnaround

Semi-Supervised Damage Localization using Deep Learning

Built a semi-supervised pipeline for post-earthquake masonry damage detection using DenseNet-201 and Grad-CAM++ localization on real post-disaster imagery without pixel-level labels.

DenseNet-201 Grad-CAM++ Computer Vision Deep Learning

99.4% Train Accuracy

70.2% Test Accuracy

Deformation Twinning in Crystalline Metals

Investigated twinning mechanisms across FCC, BCC, and HCP metals, linking stacking-fault energy, grain size, and orientation to twin nucleation, anisotropy, and tension-compression asymmetry.

Crystal Plasticity Twinning EBSD Microstructure

FCC/BCC/HCP Materials Studied

Dislocation-Density Based Modeling of Crystal Plasticity

Developed a continuum dislocation-density framework bridging discrete dislocation dynamics and continuum plasticity, implemented with a Galerkin finite element solution in MATLAB to reproduce analytical stress fields.

Dislocation Mechanics Continuum Modeling MATLAB Galerkin FEM

GND Density Evolution

Finite Element Solver for Linearized Elasticity (MATLAB)

Built a full 2D elasticity FEM solver from scratch including Q4/Q9 elements, Gaussian quadrature, global assembly, boundary conditions, and convergence validation against beam theory.

Finite Elements MATLAB Q4/Q9 Numerical Integration

Locking Mitigation Studied

SpaceX Hyperloop – Rocket-Propelled Pod Structural Design

Designed a robust load-bearing aluminum chassis and improved aerodynamic shell concept for a hydrogen-peroxide rocket-powered pod, integrating propulsion and tank supports under high-thrust constraints.

SolidWorks Inventor Structural Design CFD Concepts

40% Mass Reduction

130% Top Speed Gain

Computational Mechanics – Elastostatics & Elastodynamics (FEniCS)

Derived weak forms and implemented 2D elasticity in FEniCS with traction and displacement boundary conditions, including transient vibration decay using backward-Euler time integration and mesh convergence verification.

FEniCS PDEs Time Integration Continuum Mechanics

2D Elasticity Models

Tool Wear in Dry Hard Turning (CBN Tools)

Analyzed the influence of hardness and microstructure on flank and crater wear in hard turning across multiple steels, identifying carbide content as a key driver of abrasive wear and tool-life reduction at high speeds.

Manufacturing Tool Wear Steel Microstructure Data Analysis

2× Wear Rate Increase

Molecular Dynamics – Cu Nanoparticle Collision on Al Surface

Simulated high-speed nanoparticle impacts using LAMMPS to study dislocation formation and adhesion, analyzing defect evolution with OVITO in systems containing up to millions of atoms.

LAMMPS Molecular Dynamics OVITO Defect Analysis

~1000 m/s Impact Regime

9M Atoms Simulated

CFD Validation – Flow over Cylinder & NACA 0012 Airfoil

Validated benchmark aerodynamic phenomena including vortex shedding and stall using ANSYS Fluent, generating meshes and simulating incompressible flow across Reynolds numbers and angles of attack.

ANSYS Fluent CFD Turbulence Modeling Validation

NACA 0012 Airfoil Case

Li-Ion Batteries for EVs – Performance, Safety & Thermal Analysis

Conducted a system-level study of Li-ion batteries and emerging chemistries, assessing degradation, safety risks, and thermal management strategies to maintain cell temperatures below critical thresholds.

Thermal Management Battery Safety System Trade Study EV Energy Storage

< 50°C Target Cell Temp

AlphaTech – Kava Smart Mug Product Development

Co-founded a student startup to design and commercialize a portable self-brewing, temperature-controlled smart mug. Led mechanical design and prototyping, heating integration, and manufacturing planning with a full commercialization study.

Product Design Prototyping Thermal Systems Commercialization

11 mo Profitability Projection

2200+ Units (Year 1)

Direct Metal Deposition (DMD) – Additive Manufacturing Survey

Produced a comprehensive review of laser-assisted additive manufacturing focused on DMD, examining melt pool dynamics, process parameters, hybrid control, and process-property correlations.

Additive Manufacturing DMD Process Optimization Literature Review

74 pages Technical Report

Valve Redesign – DFM/DFA Optimization

Co-led a DFM/DFA redesign of a 10-part valve assembly, introducing a twist-lock mechanism to reduce part count, improve manufacturability, and increase assembly efficiency while reducing manufacturing index.

DFM/DFA Tolerance Analysis ANSI Fits Axiomatic Design

45% Assembly Efficiency

31% Efficiency Gain

HTS Dipole Magnet Design (YBCO) – COMSOL Multiphysics

Designed a high-temperature superconducting dipole magnet using YBCO coils and coupled EM-thermal-structural simulations. Verified field uniformity, cryogenic stability, and structural integrity under Lorentz forces.

COMSOL Electromagnetics Heat Transfer Structural Analysis

2.19 T Peak Dipole Field

20 K Operating Temp

Lumen Motors – Front Chassis Design Optimization

Re-engineered a complex sheet-metal concept into a tubular-frame architecture for an EV prototype front chassis, achieving major weight reduction while maintaining strength and a functional crumple zone.

SolidWorks FEA Chassis Design Manufacturability

~70% Weight Reduction

45,000 N Impact Load Case

Green Propellants – Performance, Safety & Trade Study

Co-led a comparative evaluation of green monopropellants as hydrazine alternatives, assessing propulsion performance, handling safety, and system-level improvements based on published experimental datasets.

Rocket Propulsion Trade Study Data Visualization Safety

12% Higher Isp

~50% System Improvement

Formula SAE – Intake System Design & Fuel Tank Redesign

Designed and validated intake and fuel systems for UH’s inaugural FSAE car, reducing intake pressure drop through CFD and redesigning the fuel tank with baffles and sump geometry to prevent starvation and increase capacity.

SolidWorks CFD Intake Design Fuel System

262→64 Pa Pressure Drop

70% Capacity Increase

Flip-Switch Actuation Mechanism (Belt Drive + Power Screw)

Designed a compact mechanism converting rotary motion into a precise linear stroke using a belt transmission and single-start power screw. Completed motion analysis, shaft sizing, belt-tension calculations, and assembly drawings.

Machine Design SolidWorks Power Screw Belt Drive

82.9 N Actuation Force

0.21 N·m Required Torque

Compound Reverted Geartrain Design (20 hp)

Designed a multi-stage gear reducer delivering 20 hp with high efficiency by selecting gear ratios, verifying AGMA bending/contact stresses, and completing shaft and bearing fatigue analyses.

Gear Design AGMA Fatigue Analysis Machine Elements

1750→85 RPM Speed Reduction

>95% Efficiency

Autonomous Gravity-Powered Launcher (Individual)

Designed a fully mechanical gravity-powered launcher to autonomously fire ten steel balls into a target bucket, using a mass-triggered release, timing separator wheel, and slide launcher for reliable sequencing.

Mechanism Design Energy Transfer CAD Google SketchUp

10 Projectiles

12 in Target Distance

Autonomous Gravity-Powered Launcher (Team Build)

Designed and built a foam-core based gravity-powered marble launcher with a trapdoor separator and dampening chamber, achieving consistent timing and accuracy under strict weight and height constraints.

Team Design Mechanisms Prototyping Testing

1.02–1.2 s Launch Spacing

<4 lb Device Weight

Feasibility of Solar Power in the United States

Evaluated technical and economic feasibility of solar PV and solar thermal systems, including cost trends, incentives, land-use considerations, and long-term projections for national deployment and grid impact.

Energy Systems Solar PV Techno-Economics Policy

485% PV Growth (2010–2013)

Design of Modern Aircraft – Structures & Subsystems

Produced an illustrated report analyzing aircraft structural components and subsystem integration, covering fuselage, wings, empennage, landing gear, propulsion evolution, and aerodynamic efficiency trade-offs.

Aerospace Structures Aerodynamics Systems Integration Technical Writing

Boeing/Airbus Benchmark Focus

NAE Grand Challenges – Smart Urban Infrastructure Concept

Co-led a systems-level concept for urban mobility improvements using real-time wireless sensing, adaptive traffic control strategies, and PLC-based automated parking to reduce delays and improve space utilization.

Systems Engineering Smart Mobility Sensors Control

10–15% Delay Reduction

Professional Experience

My journey in mechanical design engineering

Jan 2024 - Jan 2026

Postdoctoral Appointee

Argonne National Laboratory | Thermal & Structural Materials Modeling and Simulation

Led high-fidelity crystal plasticity finite element (CPFE) simulations in MOOSE coupled with NEML to predict stress relaxation and multiaxial creep rupture in advanced steels (Alloy 709, 316H), supporting ASME Section III, Division 5 Code qualification efforts. Built physics-informed surrogate models and calibrated constitutive behavior for direct comparison against experimental datasets.

• Ran 125+ high-fidelity MOOSE CPFE simulations with NEML for Alloy 709 and 316H creep and stress relaxation • Developed a PySR symbolic-regression rupture model for Alloy 709, improving accuracy by ~70% over Huddleston; journal article submitted • Optimized the Hu–Cocks precipitation model for 316H in NEML, achieving ~95% match to experiments • Authored 2 DOE technical reports and 1 peer-reviewed journal publication supporting DOE ART program Code adoption • Built a Gaussian Process surrogate with batch-mode uncertainty sampling for LPBF 316H, reducing prediction error by ~85%

Aug 2019 - Aug 2023

Graduate Research Assistant

University of Houston | Cullen College of Engineering

Conducted crystal plasticity finite element research to study micromechanical deformation and damage in ductile metals under multiaxial loading. Built end-to-end CPFEM workflows from Neper microstructures to Abaqus model setup, UMAT validation, calibration, and post-processing using MATLAB and Python.

• Validated 4 FORTRAN user subroutines (UMAT/VUMAT) in Abaqus implementing advanced crystal plasticity models • Developed and refined FEM models from Neper microstructures through complete Abaqus setup and execution • Calibrated 350+ CPFEM parameters and analyzed results using MATLAB and Python • Executed 935 FEA simulations on damage tolerance, contributing to 6 peer-reviewed publications

Jun 2016 - Aug 2016

Mechanical Engineering Intern

Lumen Motors | Electric Vehicle Startup

Supported chassis and suspension development for a high-end electric vehicle prototype using SolidWorks design and FEA. Worked with suppliers and integration teams to advance manufacturable front/rear chassis designs and validated assembly-level fit.

• Designed an electric luxury car front chassis in SolidWorks and validated ~45 kN resistance via FEA • Selected two metal manufacturing suppliers for front/rear chassis to initiate frame manufacturing phase • Modeled shock absorbers and control arms and integrated into master assemblies within SolidWorks • Assembled front and rear suspension systems with chassis per design specifications

Hi, I am Shahmeer Baweja

Simulation-Driven Engineering

⚙️ My Workflow ⚙️

Problem

Physics

Engineering Action

Result

About Me

Education

Focus Areas

Core Expertise

Technical Skills

FEA & Computational Mechanics

CAD & CAE Software

Meshing, Microstructure & Post-Processing

Scientific Computing

Multiphysics & Atomistics

Manufacturing, HPC & AI