Project Portfolio
- 3D-Printed Carbon-Based Composite Materials for Bioelectronic Applications
Industrial Impact: Developed a scalable, low-cost 3D printing process for producing carbon-based composite materials with tunable electrical and mechanical properties for bioelectronic devices. The technology enables rapid prototyping of customized bioelectronic interfaces, reducing development time by 60% compared to traditional manufacturing methods. The materials are compatible with existing injection molding and extrusion processes, allowing for seamless integration into existing production lines.
Wearable health monitoring devices, implantable biosensors, neural interfaces, and flexible electronics. The process reduces material waste by up to 40% through additive manufacturing techniques and offers a cost-effective alternative to traditional metal-based bioelectronic components.
- 3D Printed Composite Membranes for Water Treatment
Developed 3D-printed membrane composite materials for water treatment applications using PLA/PBAT blends with activated carbon and metal oxide additives. The membranes achieve over 60% dye adsorption efficiency with significantly reduced fouling rates compared to conventional flat membranes (87% performance retention after 10 cycles versus 53% for flat membranes). The 3D-printed architecture allows for localized turbulence, extending membrane life by up to 40%.
Industrial wastewater treatment, municipal water purification, desalination pre-treatment, and resource recovery. The membranes reduce operational costs through extended lifespan and lower maintenance requirements. Potential for licensing to water treatment equipment manufacturers.
- Sustainable Biomass-Derived Carbon/Polymer Composites for Energy Storage
Developing biomass-derived porous carbon architectures for energy storage devices, targeting the growing market for sustainable energy storage solutions. The global market for energy storage is expected to exceed $500 billion by 2030. Our approach uses agricultural waste as carbon precursors, reducing raw material costs by up to 60% while achieving comparable performance to commercial carbon materials.
Synthesis of biomass-derived porous carbon (from bamboo, sugarcane bagasse, and waste paper) with controlled pore structure and surface chemistry. The materials are compatible with existing battery and supercapacitor manufacturing equipment, allowing for rapid industrial adoption.
- 3D Printed Functional Composites with Tailored Filler Concentrations and Fiber/Filler Designs
Industrial Opportunity: Developing design guidelines for lightweight, functional composite structures using 3D printing. The technology enables on-demand production of custom parts with optimized mechanical and electromagnetic properties, reducing material waste by up to 50% compared to subtractive manufacturing. The approach is suitable for small-batch production and prototyping, offering a cost-effective alternative to traditional manufacturing methods.
Custom composite parts for aerospace, automotive, medical, and consumer electronics industries. The technology is being positioned for licensing to 3D printing service providers and composite material manufacturers.
Industry Collaboration Projects
- Dead Sea & Red Sea Minerals for Nanocosmetics
Industrial Opportunity: Developing polymer-based delivery systems for Dead Sea and Red Sea mineral extracts for cosmetic applications. The global cosmetics market is projected to exceed $800 billion by 2028, with increasing demand for natural and mineral-based products. The technology involves nanoencapsulation and controlled-release mechanisms to enhance active ingredient delivery and stability.
Premium skincare products (creams, serums, masks), hair care products, and therapeutic cosmetics. The technology is suitable for licensing to existing cosmetics manufacturers seeking to develop new product lines or differentiate their existing offerings.
- PEEK and Thermoplastic Composite Materials for Industrial Applications
Exploring high-performance thermoplastic composites (PEEK, carbon-fiber-reinforced polymers) for aerospace, automotive, and medical applications. The global market for PEEK composites is projected to reach $1.5 billion by 2027, driven by demand for lightweight, high-performance materials. Our work focuses on process optimization and material characterization to reduce production costs and improve performance.
Aerospace components, automotive parts, medical implants, and semiconductor manufacturing equipment. The materials offer superior mechanical properties, thermal stability, and chemical resistance compared to traditional materials.
Past Research/Industrial Projects
- Advanced Metacomposites for EMI Shielding and Microwave Absorption
Developing next-generation metacomposites with enhanced EMI shielding and microwave absorption properties for aerospace and 5G/6G applications. The current market for EMI shielding materials is projected to reach $9.5 billion by 2028, with demand driven by 5G rollout and increasing electromagnetic pollution. We are targeting a minimum shielding effectiveness of 60 dB with absorption-dominated performance to address secondary pollution issues.
Hierarchical and multi-layered structures utilizing bioinspired architectures, combined with machine learning for material property prediction. The approach aims to reduce material costs by 25-40% while achieving superior performance compared to conventional metal-based shields. Commercialization partners are being sought for scale-up and production.
- Microwave-Responsive Porous Carbon-Polymer Composites for Bioimplantation
Designed 3D-printed biodegradable polymer composite rib implants using PCL and porous carbon for chest wall reconstruction. The materials are compatible with existing 3D printing infrastructure and can be manufactured on-demand using patient-specific CT scans. The biodegradable nature eliminates the need for secondary removal surgeries, reducing overall healthcare costs by up to 30%.
Personalized medical implants for trauma surgery, orthopedics, and reconstructive surgery. The technology is being positioned for clinical trials and regulatory approval through partnerships with hospitals and medical device manufacturers.
- Sustainable Electromagnetic Shields Based on Biomass Sources
Developed a novel class of lightweight, sustainable EMI shielding composites using agricultural waste (bamboo, sugarcane bagasse, and waste paper cellulose) as carbon precursors. These materials achieve absorption-dominated shielding effectiveness exceeding 40 dB, comparable to commercial metal-based shields but at a fraction of the cost. The manufacturing process utilizes existing polymer compounding and injection molding equipment, requiring minimal capital investment for manufacturers.
EMI shielding for 5G base stations, consumer electronics (smartphones, laptops), automotive electronics, and aerospace components. The biomass-derived approach reduces raw material costs by 30-50% and supports circular economy initiatives. Multiple patents filed on the material composition and manufacturing process.
- Development of a Homemade Free-Space Electromagnetic Measurement System
Industrial Impact: Designed and validated an automated free-space measurement system for non-destructive testing of fiber composites. The system enables high-frequency microwave characterization of composite materials without physical contact, eliminating the need for expensive sample preparation and reducing testing time by 70%. The system is portable, cost-effective, and compatible with existing industrial testing protocols.
Quality control for composite manufacturing, materials characterization for aerospace and automotive industries, electromagnetic compatibility (EMC) testing for electronic devices. The system reduces capital expenditure by 80% compared to commercial alternatives and is suitable for both laboratory and production line environments.
- Integrated Bio-Giant Magnetoimpedance Sensor and Electronics
Co-investigator on a joint research project funded by Pakistan Science Foundation and NSFC. Developed bio-GMI sensor systems with integrated electronics for biomedical sensing applications. The technology enables real-time monitoring of magnetic fields with high sensitivity, using magnetic metallic fibers that are cost-effective and scalable for mass production. The sensor design is compatible with standard PCB manufacturing processes, reducing production costs by up to 50%.
Biomedical sensors for point-of-care diagnostics, environmental monitoring, industrial process control, and security systems. The sensors offer higher sensitivity than conventional Hall-effect sensors at a comparable cost, with potential for integration into existing electronic systems.
- Design, Fabrication, and Microwave Characterization of Tunable Microfiber Metacomposites
Developed tunable microwave metacomposites using ferromagnetic glass-coated microwires, with programmable electromagnetic response. The manufacturing process is compatible with existing textile and composite manufacturing equipment, enabling rapid scale-up for industrial production. The materials offer tunable dielectric properties, reducing the need for multiple material formulations.
Microwave antennas for 5G/6G communication systems, radar absorbing materials for stealth applications, and electromagnetic shielding for aerospace and defense sectors. The tunable properties allow for the same base material to be used across multiple frequency ranges, reducing inventory costs by up to 40%.
