Saad T.

Experience

• Design & Analysis Engineer Greybeard Corporate Solutions / Halifax Fan UK · Full-time Jan 2026 – Present 8 mos Islamabad Capital Territory, Pakistan Mechanical Design & Automation
  * Delivered 130+ centrifugal fan designs supporting a £1.2M+ portfolio across UK, USA, and China operations, including bespoke arrangements and impeller configurations in Autodesk Inventor.
  * Developed iLogic/scripts, tested and debugged automation tools in live order workflows.
  * Coordinated with purchasing, production, and clients to support delivery and resolve post-release/aftermarket issues.
  Structural Analysis & Product Development
  * Developed an FEA-driven impeller vibration prediction method with the University of Huddersfield.
  * Performed pre-stressed modal and Campbell diagram analysis in ANSYS Mechanical, including stochastic material/geometric variation studies and hammer-test validation.
  * Diagnosed vibration failures and proposed practical, cost-effective FEA-based design modifications.
• Founder and CEO OnyxLeaf · Part-time Nov 2025 – Present 10 mos Islamabad, Pakistan * Founder and engineering leadership: Lead the initiative and its mechanical/structural engineering, coordinating software and
  business teams developing a cloud SaaS platform for automated corrugated packaging analysis.
  * Simulation & ML Development: Architect the FEA platform by translating nonlinear Abaqus and MATLAB models into Python and
  OpenSeesPy solvers for automated composite analysis; lead integration of FEA-generated datasets and composite mechanics-based
  feature engineering to develop surrogate models for automated box-strength prediction, achieving 98% ML-FEA accuracy with rapid
  analysis times under 1 second [https://www.youtube.com/watch?v=MQvWqcFG5Bc].
  * Product strategy: Partner with business and software teams on technical product strategy and data-driven investor pitch decks.
  * Research and mentorship: Collaborate with NUST faculty and mentor undergraduate and postgraduate engineers in composite
  mechanics and experimental validation.
• Graduate Researcher University of Michigan-SJTU Joint Institute · Full-time Sep 2019 – Dec 2024 5 yrs 3 mos Shanghai, China * Predictive FEA: Developed a lattice model for corrugated-box buckling and failure, achieving ~90% strength accuracy with realistic damage patterns validated against compression tests.
  * Computational Mechanics: Performed multilevel paper, board, and box FEA using buckling and nonlinear Riks analyses; automated meshing, Abaqus execution, and post-processing with MATLAB, Abaqus CLI, and Python.
  * Constitutive Modeling: Developed an orthotropic multilayer beam-lattice model for sandwich structures, calibrated by strain-energy equivalence and achieving ~98% agreement with high-fidelity shell models.
  * Damage Mechanics: Modeled creasing via nodal stiffness degradation and derived failure limits for local buckling and liner–fluting stiffness mismatch.
  * Experimental Validation: Conducted tensile, four-point bending, compression, and impact testing using UTM, NI-DAQ, LabVIEW, and dataloggers.
  * US Packaging Industry Collaboration: Performed package drop testing using data loggers for impact dynamics assessment; provided structural design insights based on impact height and orientation analysis of experimental results.
  * US Packaging Industry Collaboration: Collaborated with cross-functional teams to enhance validated models and automated testing routines into a SaaS predictive packaging platform for industrial application.