Profile Details

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Hire Dr. Samuel K.

Ethiopia

USD 45 /hr

Manufacturing & Process Engineer (PhD) | R & D, Material & Process Optimization, FEA and DEM simulations.

Profile Summary

I am a PhD-qualified Manufacturing & Process Engineer specializing in the bridge between academic R&D and industrial application. With a focus on material and process optimization, I help organizations reduce cycle times, enhance product quality, and minimize waste through data-driven engineering and advanced numerical simulations. Core Expertise My consultancy services are built on a foundation of scientific inquiry and industrial pragmatism: • R&D Strategy: Leading product development from initial material selection through to pilot-scale production. • Process Optimization: Utilizing Lean Six Sigma and Design of Experiments (DOE) to identify bottlenecks and maximize throughput. • Advanced Simulation: Expertise in FEA (Finite Element Analysis) and DEM (Discrete Element Methods) to predict performance and optimize resource efficiency before physical prototyping. • Material Characterization: Analyzing properties to ensure structural integrity and compliance with international standards (ISO/ASTM). Why Work With Me? I specialize in transforming complex manufacturing challenges into actionable, simulation-backed solutions. Whether you need a comprehensive literature review for a new material, a virtual stress test of a component via FEA, or a full audit of your production efficiency, I provide the technical depth required to deliver measurable ROI. Primary Technical Tools: • Simulations: Abaqus, COMSOL Multiphysics. • Modeling/Optimization: MATLAB, SolidWorks, AutoCAD. • Data Analysis: Minitab, MATLAB, JMP, SQL. Available for: Independent consulting, R&D project leadership, technical reporting, and simulation-based validation.

Subject Matter Expertise

• ☆ Engineering Education
• ☆ Engineering Physics
• ☆ Engineering Thermodynamics/Thermophysical Engineering
• ☆ Industrial Engineering
• ☆ Manufacturing
• ☆ Manufacturing Optimization
• ☆ Process Control
• ☆ Statistics
• ☆ Statistical Theory
• ☆ Applied Statistics
• ☆ Comparative Analysis
• ☆ Regression Analysis
• ☆ Multivariate Analysis
• ☆ Nonlinear Regression
• ☆ Statistical Computing
• ☆ Mathematical Statistics
• ☆ Survey Design
• ☆ Study Design
• ☆ Statistical Review
• ☆ Applied Mechanics
• ☆ Theoretical Mechanics
• ☆ Fracture Mechanics
• ☆ Particle Physics
• ☆ Theoretical Physics
• ☆ Applied Physics
• ☆ Mass Transfer
• ☆ Process Engineering
• ☆ Engineering Design
• ☆ Industrial Design
• ☆ Industrial Management

Services

• Writing
• Research
• Data & AI
• Product Development

Writing Technical Writing

Research Meta-Research, Feasibility Study, Fact Checking, Gap Analysis

Data & AI Statistical Analysis

Product Development Formulation

Work Experience

Assistant Professor

Wolkite University

August 2024 - Present

Lecturer

Adama Science and Technology University School of Mechanical, Chemical and Materials Engineering

July 2014 - Present

Education

Ph.D. in Manufacturing Engineering

Adama Science and Technology University - Ethiopia

October 2020 - July 2024

MSc. in Manufacturing Engineering

Adama Science and Technology University - Ethiopia

October 2017 - July 2018

BSc. in Mechanical Engineering (Manufacturing Engineering)

Adama Science and Technology University - Ethiopia

September 2009 - July 2014

Certifications

• Master Class for Teaching Online (Open edX)

  EdPlus | ASU Online

  https://www.eventbrite.com/o/asu-online-790244257

  May 2025 - Present

Publications

JOURNAL ARTICLE

Abebe, S.K., Tufa, H.B. & Sinha, D.K. Physical, mechanical and tribological behavior of metal matrix hybrid composite fabricated via friction stir consolidation process: an integrated DEM simulation with optimization and validation. Int J Interact Des Manuf (2024). https://doi.org/10.1007/s12008-024-01904-0 .

Samuel Kefyalew Abebe, Habtamu Beri, Devendra Kumar Sinha, Ali A. Rajhi, Nazia Hossain, Alaauldeen A. Duhduh, Shaik Zainuddin, Gulam Mohammed Sayeed Ahmed (2023). Wear Behavior of AZ61 Matrix Hybrid Composite Fabricated via Friction Stir Consolidation: A Combined RSM Box–Behnken and Genetic Algorithm Optimization . Journal of Composites Science.

Samuel Kefyalew Abebe, Habtamu Beri, Devendra Kumar Sinha, Ali A. Rajhi, Nazia Hossain, Alaauldeen A. Duhduh, Shaik Zainuddin, Gulam Mohammed Sayeed Ahmed (2023). Wear Behavior of AZ61 Matrix Hybrid Composite Fabricated via Friction Stir Consolidation: A Combined RSM Box–Behnken and Genetic Algorithm Optimization . Journal of Composites Science.

Samuel Kefyalew, Betelhem Haymanot Maryam, Devendra Kumar Sinha, Satyam Shivam Gautam, Santosh Kumar, Sarang Pande(2023). AZ31-Mg metal matrix composite in metallurgical and testing approaches . Advances in Mechanical Engineering. 15. (7). {SAGE} Publications

Samuel Kefyalew Abebe, Devendra Kumar Sinha, Habtamu Beri Tufa, Getinet Asrat Mengesha(2023). Physical and mechanical behavior of aluminum-magnesium alloy matrix hybrid composite fabricated through friction stir consolidation process . Advances in Mechanical Engineering. 15. (6). p. 168781322311800. {SAGE} Publications