Sikander Naseem

About

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I'm a mechanical engineer who keeps building the software the engineering needs.

Metal additive manufacturing and simulation — laser powder-bed fusion process development, forming and joining, and more recently the electrochemistry of battery cells. MSC Marc with Fortran user subroutines where the physics has to be written by hand, ANSYS and SolidWorks where it does not, and CT, SEM, EBSD and metallography to hold the model against the actual part.

That has grown into applications built end to end — a slicing studio for LPBF, a life-cycle assessment tool on openLCA, a workspace for running language and image models offline — with a second layer of smaller utilities underneath that unblock the app work and the engineering itself.

What I work with
MSC Marc / MentatFortran subroutinesANSYSSolidWorks MATLABPythonRustReact LPBFGenerative designCT / SEM / EBSD

Career Projects

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Fifteen projects with industry and research partners, oldest first.

Heat exchanger joint

Forming, joining and fatigue of a heat exchanger joint, 2019-2021.

Spatter and process DOE

High-speed imaging of the melt pool, with a machine builder.

Bipolar plate forming

Simulation and validation for hydrogen fuel-cell plates.

TPMS valve trim

Minimal-surface trim, for a control valve manufacturer.

AM circularity

Scrap to qualified powder to printed parts, with a powder producer.

Battery simulation

Coin cell electrochemistry in MSC Marc - ongoing.

…and nine more.

Full Stack App Projects

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Eight applications built end to end.

PowderFAB Studio

Build prep for metal LPBF - ingest, orientation, overhang analysis.

PowderFAB Slice Studio

Slicing behind a Rust engine and a browser 3D frontend.

SnapLCA

Life-cycle assessment on openLCA, modelled as a node graph.

SikSense Studio

Language and image models running completely offline.

The Returned

A 2D action roguelite in Godot - every asset kit swappable by contract.

Robustimizer

Surrogate-based robust optimization, ported from MATLAB.

LPBF Cost Calculator

Multi-part print cost, entirely client-side.

Porous Powder Modeller

Porous particle beds as true STEP B-Rep geometry.

Small Apps

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Single-purpose tools written to debug or unblock something larger.

CLI / SLC Vector Viewer

A standalone 2D viewer for the files a slicer exports.

Porosity Analyzer

Measures porosity from micrographs, scale bar and all.

Marc Table Generator

Builds MSC Marc Mentat table files with up to four independent variables.

Marc Runner

Run, check and post-process MSC Marc without opening Mentat — four scripts.

Résumé

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Get in Touch

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Got a project that lives between hardware and software? I'd love to hear about it.

Design, analysis and the code that ties them together — happy to talk through anything from a single bracket to a full automation pipeline.

Play

Page coming soon

Leonardo's Contraption — a three-stage mechanism.

Decode the cryptex, align the astrolabe rings, then wind the gear crank to open the vault. Built for the fun of it, and because mechanisms are the thing I like drawing most.

Stages

Cryptex

Dial the letters to the secret word.

Astrolabe

Align the rotating rings to the marks.

Gear crank

Wind the train to release the vault.

Home / About

About

Overview

I'm a mechanical engineer who keeps building the software the engineering needs.

Most of my work sits in metal additive manufacturing and simulation — laser powder-bed fusion process development, forming and joining, and more recently the electrochemistry of battery cells. That runs through MSC Marc with Fortran user subroutines where the physics has to be written by hand, ANSYS and SolidWorks where it doesn't, and characterisation by CT, SEM, EBSD and metallography to hold the model against the actual part.

That has grown into a set of applications built end to end: a build-preparation and slicing studio for LPBF with a Rust engine behind a browser frontend, a life-cycle assessment tool on openLCA that models recycling loops as a node graph, a desktop workspace for running language and image models completely offline, and a print-cost calculator that parses CAD in the browser.

Underneath those sits a second layer of smaller utilities, written to unblock the applications and the engineering work itself. A porosity analyser to streamline and reduce file handling for large datasets. A solver runner that submits and runs custom decks and user subroutines. A viewer that reads exported files rather than internal state, so what you see is what the machine would actually be handed.

Nearly all of it has been run with industry and research partners — machine building, heat pump manufacturing, sustainable energy and storage systems, high-end flow components, medical implants, waste recycling and student racing teams — which means it has to land as something someone else can use: a printed part that fits, a report that holds up, or an application they can open and run.

Simulation & analysis
MSC Marc / MentatFortran user subroutinesANSYS WorkbenchFEAForming simulationElectrochemical modellingFlow calculationsDesign of experimentsMATLAB
Design & manufacturing
SolidWorksGenerative designIndustrial LPBF systemsTPMS & latticesTopology optimisationSTEP / STL / 3MF3D scanning
Software
PythonRustJavaScriptReactFastAPIWebGLCadQuery / OCCTtkinterNumPyopenLCA
Characterisation
CT scanningSEMEBSDMetallographyHigh-speed imagingImage analysisMechanical testing
© Sikander Naseem · Mechanical Engineer & Developer · Vibe coding through life