Abdelmoniem Abutalib

Senior Product Design Engineer Magna International-Cosma (March 2014 – June 2024):

• Provided support to COSMA divisions, through onsite and virtual workshops, to find and implement cost-reduction ideas including the Stamping Material Cost Reduction Audit. Developed necessary documentation to catalog and document VA/VE ideas for BMW, GM, Tesla, VW, Honda, Stellantis, and Volvo.
• Trained and supervised three interns and one junior product design engineer.
• Responsible for the design development of COSMA SOLAR TRACKER. Designed and released tracker roll-formed support structure, welded sub-assemblies and supported the fasteners’ procurement and the tracker drive system components selection.
• Managed and supported the program timeline of the R&D study for developing an extruded aluminum bumper beam.
• Reviewed CAE results and led the design direction to achieve targeted performance.
• Initiated design development of aluminum side doors and the windshield frame for the next-generation Jeep Wrangler.
• Benchmarked entry door designs of competitors that have similar vehicle structures.
• Served as an engineering liaison between Stellantis and Cosma. Provided engineering support to the Chrysler project to interface with COSMA Design and CAE activities. Responsibilities included: updating the engineering bill of materials, providing design and direction on CAE recommendations, evaluating design changes, and supporting design review meetings.
• Obtained, cataloged, and compared static, fatigue, and high strain rate material properties from flat stock and formed components to support vehicle testing and CAE modeling efforts during all stages of vehicle development.

Senior Assembly Process Engineer Magna International-Cosma (January 2011 – March 2014):

• Managed the implementation of the assembly process Simulation through Visual Components 3DCreate software. Led the process of selecting suitable simulation software. Developed Cosma Engineering library of assets using 3DCreate.
• Developed business cases for new projects by providing manufacturing support through assembly build sequence, 2D/3D layout, estimation of production times, direct labor requirements, and related cost information. E.g.: R&D Alum/Steel doors study and Cosma Small Car project.
• Provided manufacturing support for the Cosma Small Car project. Coordinated the creation of the body shop 3D layout, detailed simulation of part of the body shop (4 lines), and the creation of the rendered video representation of the simulation. Developed the assembly build sequences and the Auto-Cad 2D- Layouts for the closure assemblies (Entry Doors, Hood, and Liftgate). Generated the capital and tooling estimate sheet.

Senior FEA Engineer Magna International-Cosma (September 2000 – January 2011):

• Performed roof crush simulation, rear bumper impact tests, seat belt-pull, and child tether simulation on NISSAN Armada body structure design, in compliance with FMVSS, CMVSS 215, and Nissan vehicle requirements.
• Provided structural analyses on Nissan Armada Body design using NASTRAN to evaluate body mount static and dynamic stiffnesses, identify body structure natural frequencies, and floor pressure.
• Analyzed and compared two distinctive GM frame designs using Linear Static Analysis.

Project Engineer (FEA) Lexel Engineering (October 1999 – October 2000):

• Finite element modeling of different automotive components (BIW, chassis, and closures) for durability, modal, and crashworthiness analyses.
• Modeling and analysis of a flex plate for an automatic transmission using HYPERMESH and NASTRAN.

Research Engineer Center for Advanced Materials, Tuskegee University (August 1995 – August 1999):

• Designed and manufactured composite materials for armor applications using cost-effective techniques of Vacuum Assisted Resin Infusion Molding (VARIM) and Vacuum Assisted Resin Transfer Molding (VARTM).
• Assisted in the design and development of a heavy-duty fixture for ballistic impact resistance, as well as the high velocity measuring instrument.
• Performed high velocity (500-1000 M/S) ballistic impact tests on composite armor systems used in armored vehicle applications.
• Developed an analytical model to predict the high-velocity impact response of composite armor systems using MATLAB.
• Performed non-destructive evaluation tests using Ultrasonic C-scanning and optical microscopy to evaluate and correlate damage size and evolution to the impact energy.
• Supervised laboratory work as a teaching assistant for undergraduate mechanical engineering students.
• Managed a high school summer program, sponsored by the School of Engineering.

• Master of Science in Mechanical Engineering
  • Tuskegee University, Tuskegee, Alabama
    Thesis: Ballistic impact performance of a two-component composite armor
• Bachelor of Science in Mechanical Engineering
  • University of Khartoum, Khartoum, Sudan
    Project: Use of biogas as fuel for internal combustion engine