MR.Md Munim RayhanROBOTICS & CONTROLS
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PROJECT / 04 · Feedback control · Modeling · Manufacturing

Closing the loop in additive manufacturing

Experimental thermal feedback for wire-arc deposition and physics-guided parameter estimation for cold-spray simulation.

Mechanical Engineering PhD · Florida International University · 2025Published research
  • Feedback control
  • Data acquisition
  • Thermal sensing
  • Parameter estimation
  • Python
A physical welding experiment viewed through Intel RealSense L515 RGB, infrared, and depth streams.

01 / THE CHALLENGE

A physical engineering problem

Manufacturing conditions evolve during a build. Measurements can make control decisions responsive to the process, while calibrated models help connect experiments to simulation.

02 / MY CONTRIBUTION

What I worked on

  • Developed and experimentally evaluated interlayer thermal feedback for wire-arc directed energy deposition.
  • Used temperature measurements to adjust dwell time during fabrication.
  • Developed a physics-guided parameter-estimation framework for cold-spray simulation.
  • Connected sensing, data acquisition, experimental analysis, and numerical modeling in first-author publications.

RECORDED DEMONSTRATIONS

Inside the system

Thermal imaging and temperature acquisition

FLIR thermal imaging and software temperature readout during a manufacturing experiment.

Deposition thermal-field simulation

Thermal-field simulation of a deposition pass and subsequent cooling.

03 / SYSTEM WORKFLOW

Wire-arc thermal feedback workflow

  1. 01

    Measure

    Acquire interlayer temperature

  2. 02

    Assess

    Evaluate the measured thermal state

  3. 03

    Adjust

    Update dwell time through thermal feedback

  4. 04

    Evaluate

    Compare the observed process response

04 / ENGINEERING DECISIONS

Decisions behind the implementation

Use measured process state

The wire-arc work uses interlayer temperature feedback to adjust dwell time during fabrication.

Connect models to measurements

The cold-spray work estimates simulation parameters using a physics-guided framework.

Make results inspectable

The methods and evaluations are documented in peer-reviewed publications linked below.

05 / OUTCOME

What the work demonstrates

Completed a PhD in Mechanical Engineering at FIU in May 2025, with research connecting experimental sensing, feedback control, and manufacturing simulation.

Related publications

  1. 01Read paper
  2. 02Read paper

Research conducted in FIU's Department of Mechanical and Materials Engineering with co-authors and collaborators.

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