Essam Shehab

• PhD CEng FIET FACostE FHEA
• Head of Department at Nazarbayev University

This paper aims to present a detailed Digital Twin (DT) framework indicating important implementation steps and providing insights into DT technology that improves operational efficiency, optimizes performance, and creates a user-friendly platform for real-time monitoring. This project is conducted in collaboration with TechnoGroupService (TGS) com...

Digital twin and additive layer manufacturing plays a vital role of the fourth industrial revolution. Digital twin is the ideal solution for data-driven optimisation of additive manufacturing challenges. It is helpful in understating, analysing, and improving 3D printing machining process variables and consequently reducing the number of trial-and-...

This paper offers a comprehensive overview of recent advancements in digital twin technology applied to additive manufacturing (AM), focusing on recent research trends, methodologies, and the integration of machine learning. By identifying emerging developments and addressing challenges, it serves as a roadmap for future research. Specifically, it...

Additive Manufacturing (AM) is becoming increasingly prevalent in diverse industries due to its ability to manufacture intricate and unique components at lower production costs. Despite its advantages in design flexibility and waste reduction, AM presents new challenges in real-time visibility, control mechanisms, and user interfaces. While existin...

Warpage is one of the prominent issues in Fused Filament Fabrication. The cause of this is the rapid cooling of the polymer during extrusion. The residual thermal stresses accumulated within the print part result in a shape distortion and subsequent detachment of the object from the print bed. In this study, both experimental and numerical approach...

Emerging technologies and opportunities of the fourth industrial revolution and Industry 4.0 enable companies to become more digitized. Maturity models have been developed to help organisations to assess their readiness for Industry 4.0 across various dimensions. However, there is a lack of research addressing the relationships between such dimensi...

This paper highlights the development of a multi-material Selective Laser Sintering (SLS)-based 3D printer for polymer powder. It elaborates on the technical approach of the design of an additive system on the utilization of polymer powder. This type of SLS printer is rare in the market due to its difficulties in controlling chamber temperatures as...

Industry 4.0 is a complex and broad concept that affects many parts of the business, such as processes, customers, and business models, through various enablers, advanced technologies, and practices. Despite the high investment cost of Industry 4.0, many developed countries and large enterprises are already taking advantage of it. In contrast, deve...

In pursuit of industrial digitalisation, the manufacturing industry is going through a transformation in the methods for product definition from the traditional two-dimensional drawing to three-dimensional digital model known as the model-based definition (MBD). The real benefit of this digitalisation lies in the adoption of model-based definition...

Digital twin (DT) and additive manufacturing (AM), also known as 3D printers, are most important practices in industry 4.0. 3D printers are the best candidate for manufacturing geometrically challenging products due to the increase in customized product. However, there are limitations and issues regarding product quality and process optimizations....

This study reviews the essential aspects of implementing Additive Manufacturing in the construction sector by highlighting the key benefits and challenges. A comparative review allows identifying the leading technologies and prospects that have been utilized in this particular area. In recent years, research into the application of 3D printing in t...

FDM 3D printers with the ability of multi-material fabrication open great opportunities for designers and engineers to produce composite products that have properties tailored to customers’ requirements. In addition, a multi- nozzle-type printer can facilitate the manufacturing process by producing support structures for overhanging parts. In any c...

Machine learning is gaining more popularity in the FDM process in the way of performance enhancement. The multi-functionality of multi-material printing and its rising employment makes the Machine-Learning (ML) tool more attractive as the diversity of process parameters involves many fabrication combinations. This paper describes the implementation...

Additive manufacturing is a relatively new technology that is already widely applied in engineering and has a great potential to be implemented in the footwear industry. Indeed, significant improvements in the quality of 3D printed parts contribute to the quality enhancements on additive manacling in footwear industries, and the fabrication of inso...

Additive manufacturing is a promising manufacturing process with diverse applications, but ensuring the quality and reliability of the manufactured products is a key challenge. The digital twin has emerged as a technology solution to address this challenge, allowing real-time monitoring and control of the manufacturing process. This paper proposes...

Fiber-reinforced composites, such as carbon and glass fibers, are widely used across various industries. This is mainly a result of their outperforming properties in contrast with traditional materials. As a response to the environmental legal enforcement of the recycling of composite materials, several recycling methods such as mechanical, thermal...

Everyday millions of people perform office work with long sitting in front of computers. This results in a poor posture in the spinal which is normally called Kyphosis. This problem becomes significant when the upper back of the spine crosses the angle of 5 degrees. Among the types of poor postures, there is one as slouching. Slouching for a longer...

The increasing application of carbon fibre-reinforced polymer composites (CFRP) across different industries raises environmental concerns. It requires focussing on the end-of-life phase of the product/material. The environmental benefits of CFRP recycling over conventional ways of treatment are apparent. However, estimating the environmental impact...

This study focuses on the development of a large-dimensional 3D printer and its challenges in general. The major Fused Deposition Modeling (FDM) printers focus on printing small-scale parts due to their challenges in printing large-scale objects using thermoplastic polymer filaments. A novel large-dimensional multi-extrusion FDM printer is develope...

Sustaining Digital Transformation processes is a significant challenge for all organisations, especially in the manufacturing sector. Undoubtedly, Digital Transformation (DT) is becoming increasingly crucial for successfully implementing manufacturing operations. This paper discusses Digital Culture’s role in sustainable digital transformation proj...

At the time of unprecedented development of digital technologies, business owners across various industries need to stay up-to-date in terms of using cutting-edge technologies such as Industry 4.0 to ensure competitive performance. There are still many areas where their positive implications of digital technologies have not been applied. For exampl...

A digital twin is among the fast-growing technologies capable of increasing the dynamic development of manufacturing industry in terms of digital transformation in the context of Industry 4.0. The development of digital twin technologies for carbon fiber composites (CFC) recycling is a novel direction that significantly improves the recycling proce...

This research paper aims to improve the quality of 3D printed parts made of the wax filament by implementing the Taguchi orthogonal array process optimization method. The manufactured parts can be used as cost-effective investment casting patterns. With the Taguchi method, it was concluded that the nozzle temperature has the most effect on the dime...

Digital transformation is of crucial importance in the manufacturing industry, especially after the COVID-19 pandemic because of the increasing need for remote working and socially distanced workplaces. However, there is a lack of a clear and well-defined process to implement digital transformation in manufacturing. This paper aims to identify the...

Selective laser melting method occupies a special place in powder bed fusion technology. The growing widespread interest in this technique is due to its several favorable benefits. The final near to net-shape product, which has up to 99.9% relative density is the key advantage. With the extensive applicable materials, PBF–LM has feasible economic b...

This paper presents the current development and formulate the future direction of selective laser melting (SLM) technology in the aerospace industry. The potential application and challenges of SLM in producing aerospace industry components, their key requirements, and the mechanical properties of the built parts were discussed. SLM technology can...

This research paper aims to improve the quality of 3D printed parts made of the wax filament by implementing the Taguchi orthogonal array process optimization method. The manufactured parts can be used as cost-effective investment casting patterns. With the Taguchi method, it was concluded that the nozzle temperature has the most effect on the dime...

The Fourth Industrial Revolution, also known as Industry 4.0, stems from the rapid advancement of digital technologies such as the Internet of Things and Cyber-Physical Production Systems. It has the potential to weave positive changes to firms and impact organizational structure layers. Therefore, it provides an impetus for the collaboration of fa...

Purpose In recent years, 3D printing technologies have been widely used in the construction industry. 3D printing in construction is very attractive because of its capability of process automation and the possibility of saving labor, waste materials, construction time and hazardous procedures for humans. Significant researches were conducted to ide...

Industry 4.0 requires companies to go through a complex transformation. Numerous maturity models offer to measure the readiness of an enterprise for the transition to a new operation mode. However, there is a lack of research efforts in developing an advisory tool for digital readiness improvement recommendations. This study aims to create a system...

Industry 4.0 is a concept which majorly changes the industries, enterprises, the whole way of doing traditional business by transforming existing business models. However, not all developing countries are keeping up with the time, therefore many industries may leave behind. This research aims to study one of the promising but not investigated secto...

Carbon Fibre Reinforced Polymers (CFRPs) are commonly used materials in manufacturing components and products in the automotive, aerospace, and wind energy industries generating thousands of tons of waste, thus creating a threat to the environment if not recycled. Therefore, it is important for both academia and industry to investigate various ways...

Cost-effective and environmentally responsible ways of carbon fiber-reinforced composite (CFRP) recycling are increasingly important, owing to the rapidly increasing use of these materials in many industries such as the aerospace, automotive and energy sectors. Product designers need to consider the costs associated with manufacturing and the end-o...

The use of carbon fiber reinforced polymers (CFRPs) has expanded in many industries due to superior properties compared to traditional materials. Nevertheless, their recycling is challenged by immature recycling market and poor legislative support. This study evaluates the application and disposal of CFRPs within the different industries in Kazakhs...

This paper highlights the findings of multi-material application in 3D printed specimens. The work presents experimental results of multi-material, and multi-color-based 3D printed specimens by a multi-extrusion printer developed at the laboratory. It aimed to determine the bonding properties between the layers of various materials indicated with d...

Globally the manufacturing industry is undergoing a shift in the way product specifications are defined, used, and re-used from conventional drawing-based systems to a comprehensive 3D digital product model. This transformation is at the heart of the digitization processes. The true benefits lie in the adoption of this technology throughout the pro...

The successful operation of Electric-Vehicle Batteries (EVB) is paramount for the ever-continuing goal of approaching a low carbon emission future. The Lithium-ion battery (LIB) is currently the best wager to implement on Electric Vehicles (EV). Nonetheless, it comes with its fair trade of challenges. The complexity involved in the design, manufact...

Over the years, there has been an advancement in how manufacturing companies conduct maintenance. They have begun transitioning from Preventive Maintenance (PM) to Predictive Maintenance (PdM). With the introduction of technologies such as Digital Twin (DT), Internet of Things (IoT), and Intelligent Manufacturing (IM), the world is rapidly changing...

The world is adopting digital technologies at a rapid pace which are the key enablers to improve every walk of life in the modern era. This quest for digitization has equal rigor within the manufacturing industry. 2D drawings have been used historically to define the specifications of a product for manufacturing. The evolution in digital technologi...

Recycling of carbon fiber reinforced polymer composites (CFRPs) is a trending topic in the context of the current levels of CFRPs application in different industries and evolving environmental legislation and regulations. However, the recycling processes tend to be accompanied by various uncertainties leading to an increase of difficulties in evalu...

Although digital transformation has been extensively researched in recent years, there is no clear definition, especially in the manufacturing industry. In addition, there is no oblivious model for the current manufacturing firms to be digitally transformed. As a part of a current research project, this paper proposes a framework for the digital tr...

Digital Transformation becomes an essential strategy for organisations in this new digital arena, specifically after the COVID-19 pandemic and its unprecedented effects on the whole world and the manufacturing sector. In this new digital era, consumers became more expert and more engaging in the products using new technologies. At the same time, co...

Unique properties such as high strength, wear and fatigue resistance at high temperatures have made superalloys best candidate materials for the aerospace industry. On the other hand, the development of composite materials particularly metal matrix composites (MMCs) have comparable properties to superalloys and have an advantage of being lightweigh...

The concept of Industry 4.0 is becoming more and more popular all over the world. The implementation of its assumptions in business practice changes the way companies operate. The enormous innovative potential of the Industry 4.0 concept and the intensive use of processes based on the implementation of advanced technologies in its assumptions have...

The implementation of digital transformation features is highly required to provide sustainable growth and a high level of competitiveness. One of the essential components of the ensuring of SMEs readiness for digital transformation is a digital maturity model that can assess the maturity level based on the features of SMEs in Kazakhstan. This stud...

With the evolving of Industry 4.0 in the 21st century, digitalization gains popularity in companies, because it is a need that makes the company competitive and optimizes the work. Many factors influence the company and its transformation, especially in large companies, for example, financial situation, organizational culture, employees and their s...

The digitalization has become a leading trend for developing a stable economy through industry and firm digital transformation. However, there is no unified recipe for the successful implementation of these technologies. This work aims to define Critical Success Factors of digitalization for the manufacturing industry and compare them with Kazakhst...

This study aimed to conduct a systems engineering investigation for the integration of reverse vending machines (RVM) into the waste management system of Kazakhstan. By conducting a wide-scale survey among the general public, the study was able to identify the underlining reasons for low recycling rate, the awareness and willingness of the public t...

Purpose Numerous leanness assessment models were developed for both manufacturing and service sectors. However, little research effort was made to provide an instrument that can be used to measure the leanness level of the product-service system (PSS). This paper aims to propose an index to assess the leanness of PSS in a UK manufacturing company....

The research in wearable lower limb exoskeletons is showing an increasing interest in the last few years. An exoskeleton is a structure that helps paralyzed patients stand and walk. Nowadays, wearable exoskeletons have a growing interest in healthcare, as they help make patient's rehabilitation process more comfortable and more natural. External ex...

Industry 4.0 concept is one of the growing concepts worldwide for the last five years. It combines the physical and digital world, thus creating new capabilities which affect not only the manufacturing industry but to all other sectors and organizations. Furthermore, many experts worldwide declare that Industry 4.0 will have a substantially positiv...

In order to support accelerating the diffusion of innovations in high value manufacturing related to enabling flexible mass customization, this paper presents a research-based maturity model for forecasting the speed of innovation diffusion from ideation to market saturation. The model provides an early stage applied research view of (groups of) “g...

Aircraft manufacturing industries often evolve in the ecosystem of complex designs and manufacturing processes associated with large volume of information generated along the lifecycle. Digital Twin (DT) technology has the potential of leveraging such information to provide useful insights benefiting the overall business in many ways. Information M...

Digital transformation is one of the most evolving areas both in the research literature and in industrial applications. No doubt that this process will be crucial in the survival of any manufacturing organisation in the future, especially during the current COVID-19 crisis. This paper aims to present a review of the concept in the manufacturing in...

The use of fiber reinforced polymeric (FRP) composites has increased rapidly, especially in many manufacturing (aerospace, automobile and construction) industries. The machining of composite materials is an important manufacturing process. It has attracted several studies over the last decades. Tool wear is a key factor that contributes to the cost...

Digital Twin (DT) is the imitation of the real world product, process or system. Digital Twin is the ideal solution for data-driven optimisations in different phases of the product lifecycle. With the rapid growth in DT research, data management for digital twin is a challenging field for both industries and academia. The challenges for DT data man...

3D modeling is in use for the last many decades at various stages of the product lifecycle i.e., design, analysis, manufacturing, and inspection. In the modern era of Industry 4.0 where the high-value manufacturing industry is aiming at the digital thread, Model-Based Definition (MBD) has been considered as the heart of this transformation. However...

Model-Based Definition (MBD) is being adopted by the manufacturing industry as a single source for all product information in place of conventional 2D drawings. This paper aims to review the current literature on Model-Based Definition (MBD) and Model-Based Enterprise (MBE) to recognize the main contributions towards the development and implementat...

Laser drilling is a well-established manufacturing process utilised to produce holes in various aeroengine components. This research presents an experimental investigation on the effects of laser drilling process parameters on productivity (material removal rate), hole quality (hole taper) and drilling cost. Single-pulse drilling was employed to dr...

The use of carbon fiber composites (CFCs) has become broad in many industries due to its superior properties compared to conventional materials. However, the increased demand coupled with environmental regulations has led to the development of different recycling methods for CFCs such as mechanical, thermal and chemical processes. Each recycling me...

Electro Discharge Machining (EDM) can be an element of a sustainable manufacturing system. In the present study, the sustainability implications of EDM of special-purpose steels are investigated. The machining quality (minimum surface roughness), productivity (material removal rate) improvement and cost (electrode wear rate) minimization are consid...

Laser drilling is a high-speed process that is used to produce high aspect ratio holes of various sizes for critical applications, such as cooling holes in aero-engine and gas turbine components. Hole quality is always a major concern during the laser drilling process. Apart from hole quality, cost and productivity are also the key considerations f...

Manufacturing Industry is moving towards adoption of 3D models as the ultimate authoritative source for complete product definition replacing 2D drawings, which is called “Model-Based Definition”. Starting its journey from geometric information on design, manufacturing, and inspection, the targets are to achieve the ultimate goal of lifecycle model...

In the context of aerospace digital transformation, gaining and maintaining competitive advantage has led aerospace manufacturers to change how product definition is communicated. Model-Based Definition (MBD) and Enterprise (MBE) are the next generations of product definition that aim to move from 2D drawings to a full 3D digital model. Even though...

To achieve an excellent workpiece surface quality and long tool life in machining of hardened steel is an inordinate challenge. Recently, conventional flood cooling assisted machining processes are used to address this problem. However, such proposed processes have adverse effects on the environment as well as on the machine shop worker's health. H...

Cutting fluids have frequent use in industrial sector to improve the machinability. Due to the negative impact on our ecology, recent focus has shifted to explore some environment-friendly cooling techniques such as cryogenic cooling. Cryogenic cooling involving liquid nitrogen is one of the alternative techniques which improves the efficiency of t...

With the rapid digitalisation in the aerospace industry, the emergence of Digital Twin (DT) is significant as it can facilitate the urgent need of data-driven optimisations in existing products, operations and services. Data management for a novel concept like DT is new for both academia and industry. In this paper, an efficient data management app...

Laser drilling is used to produce micro holes in various components which have widespread applications in the automotive, aerospace and medical sectors. Many researchers have examined several ways to enhance the performance of this process by investigating different process parameters that seek to improve drilled hole quality. The productivity and...

Environmental legislation puts more pressure on solving carbon fibre composites (CFC) waste management through recycling and reuse. Despite their superior properties, CFC creates environmental issue when it reaches its end of life. The aim of this paper is to to provide a framework that represents the first step towards the development of a cost mo...

Assembly Lines (ALs) are used for mass production as they offer lots of advantages over other production systems in terms of lead time and cost. The advent of mass customization has forced the manufacturing industries to update to Mixed-Model Assembly Lines (MMALs) but at the cost of increased complexity. In the real world, industries need to deter...

Electrical discharge machining is a non-traditional machining method broadly employed in industries for machining of parts that have typical profiles and require great accuracy. This paper investigates the effects of electrical parameters: pulse-on-time and current on three performance measures (material removal rate, microstructures and electrode...

Parametric modelling and optimisation play an important role in choosing the best or optimal cutting conditions and parameters during machining to achieve the desirable results. However, analysis of optimisation of minimum quantity lubrication–assisted milling process has not been addressed in detail. Minimum quantity lubrication method is very eff...

In practice cost estimators typically assume that cost risk and uncertainty continuously decrease across the whole product life cycle. Industry case studies and semi-structured interviews indicate that while cost risk and uncertainty decreases between technology readiness levels / stage gates, it increases when technology readiness levels / stage g...