Projects & Research | Abdullahi Abubakar Ahmed

Structured-light scanning workflow used for dimensional validation of a PETG FDM test part

Featured Master's Thesis

Structured-Light-Assisted Dimensional Validation and Axis-Specific Shrinkage Compensation of PETG FDM Parts

My Master's thesis investigated how structured-light 3D scanning can be used to measure, analyse, and compensate for dimensional errors in PETG components manufactured through Fused Deposition Modelling.

I developed an uncertainty-aware workflow connecting CAD modelling, FDM printing, optical scanning, scan-to-CAD comparison, reverse-engineering bias correction, axis-specific shrinkage calculation, compensated reprinting, and independent calliper validation.

56% reduction in X-axis mean absolute error

53% reduction in Y-axis mean absolute error

44% reduction in Z-axis mean absolute error

The results showed that structured-light scanning can support practical dimensional compensation when calibration, registration, surface preparation, uncertainty, and feature-size limitations are treated as part of the measurement process.

Colourful modular outdoor-furniture prototype produced through 3D printing

Internship Project

3D Printing and Optimisation of a Modular Outdoor Furniture Prototype

This project focused on preparing, optimising, slicing, printing, and assembling modular components for an outdoor-furniture prototype using PETG.

I evaluated 100%, 85%, and 75% scales, compared assembled and disassembled printing strategies, and optimised settings for print time, material use, fit, and structural integrity.

9 CFU officially awarded

26% time reduction at 85% scale

28.6% material reduction at 85% scale

The 85% scale provided the best balance between production savings and assembly precision. The final prototype was assembled from colour-coded modular parts printed with Zortrax M300 Plus and Raise3D systems.

Hydrogen storage tank modelling project showing the tank model, assumptions, numerical methods, and pressure, temperature, and mass results

Sustainable Energy Project

Modelling of a Hydrogen Storage Tank

I developed a MATLAB-based transient model to analyse the thermodynamic behaviour of a hydrogen-storage tank under changing operating conditions.

The model applied mass and energy conservation equations to calculate pressure, temperature, and mass changes over time. I implemented a fixed-step fourth-order Runge-Kutta method and compared its results with MATLAB's adaptive ode45 solver.

The project strengthened my understanding of hydrogen-storage thermodynamics, numerical accuracy, transient simulation, and safety considerations relevant to hydrogen-refuelling infrastructure.

Interested in my technical work?

I am open to research and engineering opportunities involving additive manufacturing, dimensional metrology, hydrogen technologies, numerical modelling, and sustainable energy.

Contact me