Mechanical design & CAD
From concept geometry to detailed assemblies, drawings, and design validation.
3D modeling · 2D drafting · Design for manufacturing
Mechanical engineering consultingComplex challenges.
Complex challenges.
Engineered solutions.
Mechanical design, advanced simulation, and custom software to turn engineering questions into practical decisions.
From flow insight to design.
Steam-drum CFD investigation
SELECTED WORKSteam-drum CFD investigation
Simulation + engineering
Mehrdad Zare · Mechanical Engineering ConsultantCAD / FEA / CFD / Optimization / Code
01 / ExpertiseEngineering depth.
Engineering depth.
Practical application.
Support from concept development through analysis, design refinement, and technical documentation.
Finite element analysis
Understand structural behavior, identify failure mechanisms, and evaluate design changes.
Stress · Thermal · Fatigue · Buckling · Vibration
Computational fluid dynamics
Investigate flow, heat transfer, and thermal performance across operating conditions.
Multiphase flow · Cooling · Pressure drop · HVAC
Design optimization
Explore shape, topology, and material choices to improve engineering performance.
Topology optimization · Virtual prototyping · Design reviews
Engineering software
Build numerical methods and custom tools that support analysis and automate repeatable work.
Python · C++ · MATLAB · Simulation automation
Technical review & support
Investigate root causes and turn complex analysis into practical design recommendations.
Failure analysis · Technical calculations · Documentation
TOOLS & TECHNOLOGIESAnsysSolidWorksOpenFOAMMATLABPythonC++COMSOL
02 / Selected work
Analysis that informs design.
Selected industrial and research projects spanning structural mechanics, thermal fluids, and numerical methods.
CFD / DESIGN
Steam-drum redesign
Investigating nozzle cracking and vibration through transient, two-phase flow analysis.
Project details
Role: Mechanical / CFD engineer, design engineer & technical lead
Flashing condensate and turbulent flow were investigated to understand dynamic loads on the nozzle walls. The resulting design used flow-conditioning sleeves to diffuse incoming jets and damp vapor fluctuations.
FEA / FAILURE ANALYSIS
Pulsating combustion heaters
Assessing thermal and structural behavior to guide component redesign.
Project details
Role: Design engineer, technical lead & structural analyst
Linear and nonlinear FEA, stress analysis, and creep and fatigue assessments were used to investigate heater failures. Geometry and material modifications were evaluated to improve structural adequacy.
CAD / STRUCTURAL ANALYSIS
Steam-reformer support
Designing a steel structure with improved access beneath the reformer.
Project details
Role: Design engineer, technical lead & structural analyst
The proposed structure was assessed under static and dynamic loads. Modal analysis evaluated separation between the first natural frequency and known forcing frequencies.
Heat-exchanger topology optimization
Development of density-based optimization software using C++, OpenFOAM, conjugate heat-transfer modeling, and the Method of Moving Asymptotes.
Air-cooled condensing unit
Ansys Fluent modeling of air recirculation, temperature distribution, and performance across duct configurations and operating conditions.
Injection screw design & analysis
FEA and stress analysis of screw-conveyor weld failures, with redesigned connections, gussets, and pads assessed using simulation and hand calculations.
Isogeometric FEM & optimization
Research into triangular isogeometric finite elements, numerical algorithms, and AI-assisted shape optimization using C++, Python, and MATLAB.
Cardiovascular biomechanics
Finite element research into plaque vulnerability, tissue viscoelasticity, and the influence of heart rate on peak cap stress.
03 / About
Mehrdad Zare
Mechanical engineer.
Simulation specialist.
Software developer.
Connecting industrial design experience with research in computational mechanics.
My work brings together mechanical design, finite element analysis, computational fluid dynamics, and engineering software development. I help investigate failures, evaluate design alternatives, and develop numerical tools for demanding engineering problems.
2024–present
Independent engineering consultant
Simulation, design optimization, and code development.
2022–2024
Senior Design Engineer
Openso Engineering · Illinois, USA
2017–2021
Research Assistant / PhD Candidate
University of Wisconsin–Madison · Computational mechanics and optimization
2015–2016
Research Assistant / Master’s student
University of British Columbia · Cardiovascular biomechanics
Education
M.S. Mechanical Engineering — University of Wisconsin–Madison, 2021
M.S. Mechanical Engineering — University of British Columbia, 2016
B.S. Mechanical Engineering — Sharif University of Technology, 2013
Explore published research ↗M.S. Mechanical Engineering — University of Wisconsin–Madison, 2021
M.S. Mechanical Engineering — University of British Columbia, 2016
B.S. Mechanical Engineering — Sharif University of Technology, 2013
INDUSTRIES SERVED
Oil & gas / Energy & power / Industrial equipment / Manufacturing / Process systems / Sports equipment / Biomedical
04 / Start a conversationWhat engineering challenge
What engineering challenge
are you working on?
Share your project goals, the challenge you’re facing, and your timeline. Let’s discuss how design, simulation, or software can help.