Dr. Essa holds a PhD in Mechanical Engineering from the University of Birmingham (2011), BSc and MSc degrees from the University of Alexandria, in Mechanical and Production Engineering. Following his PhD, Dr. Essa joined Partnership for Research in Simulation of Manufacturing and Materials (PRISM2) as a research staff leading research projects in cooperation with Rolls-Royce, MTC and the newly established centre CASIM2.
The majority of his research has focussed on the application of finite element (FE) modelling using ABAQUS and DEFORM software to simulate a variety of manufacturing processes such as hot isostatic pressing, additive layer manufacturing, dual-material upsetting, metal spinning and single point incremental forming (SPIF) processes. His process modelling experience extends to the use of Computational Fluid Dynamics in industrial applications using Flow-3D, ProCAST and Sigma Soft software. He developed a numerical model to predict the distortion of ceramic core during wax injection in investment casting.
His research interests include; manufacturing of auxetic structures from superelastic alloys using additive layer manufacturing for defence applications, Net-shape manufacturing using combined material processing techniques such laser fabrication and hot isostatic pressing for aerospace applications.