BASIL J. PAUDEL

Publications

• Paudel, B. J. & To, A. C., 2025 "Spatial green density variation and its effect on distortion prediction in binder jet additive manufacturing." Additive Manufacturing 98, 104640.

• Dong, W., Paudel, B. J., Deng, H., Garner, S. & To, A. C., 2024, "Data-driven distortion compensation for laser powder bed fusion process using Gaussian process regression and inherent strain method." Materials & Design 243, 113063.

• Paudel, B. J., To, A. C. & Mostafaei, A. 2024. "Chapter 13: Principles of Solid-State Sintering." in Solid-State Metal Additive Manufacturing: Physics, Processes, Mechanical Properties, and Applications 416 (Wiley-VCH GmbH).

• Paudel, B. J., Deng, H. & To, A. C. 2023. “A physics-based data-driven distortion compensation model for sintered binder jet parts considering size effects.“ Additive Manufacturing 68, 103517.

• Paudel, B. J., Conover, D., Lee, J., To, A. 2022. “A Computational Framework for Modeling Distortion during Sintering of Binder Jet Parts.” J. of Micromechanics and Molecular Physics. 6 (04) pp. 95-102. 

• Paudel, B. J., Marshall, G. J. & Thompson, S. M. 2021. “Thermal Monitoring and Modeling of Ti–6Al–4V Thin Wall Temperature Distribution During Blown Powder Laser Directed Energy Deposition. “ Journal of Manufacturing Science and Engineering 144.

• Paudel B.J., Thompson S.M., “Localized Effect of Overhangs on Heat Transfer during Laser Powder Bed Fusion Additive Manufacturing”, Solid Freeform Fabrication 2019, Austin, Texas.

• Paudel B.J, Masoomi M., Thompson S.M, “Multi-Objective Topology Optimization of Additively Manufactured Heat Exchangers”, Solid Freeform Fabrication 2019, Austin, Texas.

• Masoomi, M., Paudel B.J., Shamsaei, N., Thompson, S.M, “Establishing Property-Performance Relationships through Efficient Thermal Simulation of the Laser-Powder Bed Fusion Process”, Solid Freeform Fabrication 2018, Austin, Texas.

• Paudel B.J., Jamal T., Thompson S.M., Walters D.K., 2014, “Thermal Effects on Micro-sized Tesla Valves”, Proceedings of ASME 2014, Chicago, Illinois, USA, FEDSM2014-21929.

• Thompson S.M., Paudel B.J., Jamal T., Walters D.K., 2013, “Numerical Investigation of Multistaged Tesla Valves”, ASME Journal of Fluids Engineering, FE-13-1581.

• Thompson S.M., Jamal T., Paudel B.J., Walters D.K., 2013, “Transitional and Turbulent Flow Modeling in a Tesla Valve”, Proceedings ASME 2013 IMECE Fluids Engineering Systems and Technologies, San Diego, California, USA, IMECE2013-65526.

Presentations

• Paudel B.J., Thompson, S.M, 2019, “Localized Effect of Overhangs on Heat Transfer during Laser Powder Bed Fusion Additive Manufacturing”, Solid Freeform Fabrication 2019, Austin, Texas

• Paudel B.J, Masoomi M., Thompson S.M, 2019, “Multi-Objective Topology Optimization of Additively Manufactured Heat Exchangers”, Solid Freeform Fabrication 2019, Austin, Texas

• Paudel B.J & Sridhar K., 2018, "Airfoil-Based Progressively Tapered (APT) Additively Manufactured Heat Sink", InterPACK Conference, San Francisco, CA

ACADEMIA

Graduate Research Assistant, Dr. Albert To, University of Pittsburgh

• • Modeling and simulation of distortion during sintering of Binder Jet printed parts

  • Design experiment and fabricate samples using ExOne Innovent BJ printer

  • Develop geometry compensation algorithm to mitigate distortion during sintering process

Graduate Research Assistant, Dr. Scott M. Thompson, Auburn University

• • Thermal simulation of transient LPBF based additive manufacturing (AM) process

  • Design and study AM-ed heat sink/exchangers; use thermal topology optimization

  • Presented research work in university symposiums as well as conferences

  • Develop a low fidelity simulation model for AM

  • Peer-reviewed research related journals and publications

  • Designed, additively manufactured, post-processed and heat-treated samples for experiment validation

Teaching assistant

• • Taught ‘Fluid Dynamics’ (1 lecture) and graded quizzes (Dr. Thomas Burch, Spring 2018)

  • Delivered a lecture to students in ‘Heat Transfer’ course (Dr. Scott Thompson)

Undergraduate Research Assistant, Dr. Scott M Thompson, Mississippi State University

• • Designed and modeled a study to investigate the thermal effects on a mini-scale Tesla valve; generated a scientific report on the study and published it in ASME proceedings

  • Conducted design analysis using ANSYS FLUENT on various Non-Moving Passive Tesla Valve designs; both laminar and turbulent flow models were considered in the study 

  • Created macros in SOLIDWORKS to automate design of multiple Non-Moving Passive (NMP) Tesla valves

  • Coded a batch software in Visual Basic to automatically generate code for FLUENT journal file

  • Used COMSOL MultiPhysics to study the Piezo energy harvestor on a Flat-Plate Oscillating Heat Pipe

Teaching Assistant, Andrew Walters, Mississippi State University

• • Assisted students in learning the course content/assignments for EM 2413 (Statics)

  • Assisted instructor with classroom management; Proctored students in classroom tests

Grader, Dr. Rogelio Luck, Dr. Heejin Cho, Dr. David Marcum and Dr. Kalyan Srinivasan 

• • Graded assignments, projects and/or Tests for courses ME3613 (System Dynamics), ME3113 (Engineering Analysis), ME3513 (Thermodynamics I), ME3313 (Heat Transfer)

INDUSTRY

R&D Engineer II, ANSYS Inc,

Additive Manufacturing Summer Intern, ANSYS Inc,

Software Development (MAPDL) Summer Intern, ANSYS Inc,

• • Develop numerical model using ANSYS usermat module

  • Validate the model with experiments from literature

Engineering Consultant, Prime Manufacturing/Wenzel Downhole Tools Ltd.

• • Performed design study on a Bi-center bit; Conducted force balancing of cutters in the bit

  • Analyzed fluid flow for possible cutter cleaning issues and recirculation zones

Mechanical Design Engineer, Cesar I. Hernandez, OTS International Inc.

• • Performed engineering calculations and documentation tasks such as product specifications calculation, 3D modeling, detailed assembly drawing, internal manufacturing instructions, bill of materials creation, and engineering release packages in compliance with ISO-9001

  • Conducted fluid flow analyses in various stages of product design using CFD tool (FloEFD for CREO); studied both water-based and oil-based mud (Non-Newtonian fluid) to look for potential cleaning issues due to fluid re-circulation and cutter failure to heat due to insufficient cooling

  • Conducted particle studies (one-way) to evaluate wear/erosion in the bit body, and studied the duration of its stay within the target region for understanding hole cleaning issues

  • Researched and analyzed application/rock data from customer to propose product with optimal cutting efficiency; developed methods for conducting experiments on new and modified designs

  • Designed and programmed a software using Visual Studio .NET to automate cutting structure generation as well as evaluate diamond density and relative cutting force reducing product design time and improved performance; software had the ability to interface with CREO, Excel, and export in IGES format

  • Designed tools and product assemblies for Oil and Gas industry such as drill bits, bi-centers, reamers, stabilizers while meeting customer’s requirement and industry specifications API 7-1, API 7-2, API RP 7G

  • Implemented full product lifecycle including application research, product design and analysis, manufacturing, quality, post-run analysis and wrote reports suggesting product improvement

• Proficient in constitutive modeling using ANSYS USERMAT module

• Operating capability of Additive Manufacturing machines: EOS M290 and RENISHAW AM250

• Operating capability of manual machining tools: Milling, Grinding

• Proficient in Pro Engineer/Creo, FloEFD, Creo Simulate, Solidworks CAD, AutoDesk Inventor

• Proficient in ANSYS Fluent, ANSYS Structural/Mechanical APDL, MathCAD, Excel, VBA Programming/Macro

• Proficient in MATLAB, Mathematica, COMSOL Multiphysics, Visual Studio .Net, C# and C++, LabVIEW

• IADC Certified RigPass Training

• Pennsylvania Manufacturing Innovation Program Fellowship (2020-2021)

• Winner, ASME 2018 Additively manufactured heat sink student design competition

• Woltosz Fellowship (2017-2020)

• Provisional Patent on Airfoil-based progressively tapered additively manufactured heat sink (2018)

• 3rd Place, Physical Sciences and Engineering, Summer Undergraduate Research Symposium 2013

• Student Volunteer, Society of Automotive Engineers (SAE), Starkville, MS (Fall 2012-2013)

• Engineering Student Council (Member), Gamma Beta Phi Honors Society (Member)

• Phi-Theta Kappa Academic Scholarship (Fall 2011-Spring 2013), President’s Scholar (Multiple Semesters)

• Member of American Association of Drilling Engineers (AADE)

• Executive member and web manager, Nepalese Student Association-MSU (2012-13)