Professor Khamis Essa BSc, MSc, PhD, CEng, FIMechE, FHEA

Professor Khamis Essa

Department of Mechanical Engineering
Professor of Digital Manufacturing
Director of the Advanced Manufacturing Group

Contact details

Mechanical Engineering
University of Birmingham
B15 2TT

Khamis Essa is Professor of Digital Manufacturing and the Director of the Advanced Manufacturing Group at the School of Engineering, the University of Birmingham. His research is focused on advanced manufacturing technologies for instance metal and ceramic Additive Manufacturing (AM), Hot Isostatic Pressing (HIPing) and Incremental Sheet Forming (ISF). He has been developing novel manufacturing routes and applications for aerospace, defence, automotive and biomedical industries. The scientific emphasis of his research is on material and process interaction. He has been also developing holistic modelling for comprehensive understanding of process and material behaviours. His research portfolio has a research income in excess of £14M. His research has been supporting major companies across the world including Rolls-Royce, BAE Systems, MBDA, MicroTurbo, Ford, European Space Agency and Caterpillar. He has been also supporting Small to Medium enterprises through major ERDF funding programmes such as CASIM2 and SmartFub. Prof Essa has over 100 journal and conference publications in addition to three patents and two book chapters.


  • PhD in Finite Element Modelling of Incremental Sheet Forming, University of Birmingham, 2011
  • MSc in Tube Spinning processes, University of Alexandria, 2007
  • BSc in Manufacturing Engineering, University of Alexandria, 2003


Professor Essa holds PhD in Mechanical Engineering from the University of Birmingham (2011), BSc and MSc degrees from the University of Alexandria, in Mechanical and Production Engineering. Professor Essa is currently the Director of the Advanced Manufacturing Group at School of Engineering. He is also the academic lead for the University of Birmingham campus in Dubai. He was the Deputy Research Director and Employability Champion for the School of Mechanical Engineering.

Professor Essa holds Honorary Professorship from the University of Navarra  (Spain),  The Arab Academy for Science, Technology & Maritime Transport  (Egypt) and Al-Hussein Bin Talal University (Jordan). He is Charter Engineer, Fellow of the Institute of Mechanical Engineers and Fellow of the Higher Education Academy. Professor Essa is also setting in the editorial board of three journals.      Aim for no longer than 300 words and should contain more detailed information than the introductory statement, while not copying that information.


Teaching programmes

  • MEng and AME (MSc) Mechanical Engineering

Teaching coordinating the following modules:

  • Advanced Manufacturing
  • Research and Professional Skills

Postgraduate supervision

  • Additive Manufacturing of Bone-like Scaffolds (Elizabeth Iles)
  • Contactless Single Point Forming of Al alloys (Ahmed Bahabri)
  • Additive Manufacturing of novel implants (Giri Rampal)
  • Additive Manufacturing of smart stents (Ellis Williams
  • Metal Binder Jetting of Refractory Metals (Raja Abdullah Khan)
  • Additive manufacturing of biomedical implants (Abdullah Mohammed)
  • Additive Manufacturing of Dental Prosthesis (Ahmed Binobaid)
  • 3D printing of smart and transparent ceramics (Michele De Lisi)
  • Contact-less Single Point Forming (Mohammad Almadani)
  • Numerical Modelling of Powder Filling and Consolidation in Hot Isostatic Pressing (Abdullah Alqahtani)
  • Incremental Sheet Forming of high temperature alloys (Weining Li)
  • Additive Manufacturing of monolithic catalyst for fuel reforming (Nikolina Kovacev)
  • Hybrid manufacturing of high value components (Aldi Mehmeti)
  • Smart contact lenses (Yousef Alqurashi)
  • Optical Biosensors (Mohamed Elsherif)
  • Additive manufacturing of smart materials (Chaolin Tan)
  • Finite Element Modelling of Dynamic Tire Structures (Hamad Aldhufairi)
  • Development of Mesh Type Cushion for Multi Point Forming (Abror Tolipov)
  • Development and Optimisation of Multi Point Forming (Mohamed Abosaf)
  • Residual Stresses in Multi Point Forming (Ali Elghawail)
  • Additive manufacturing and powder HIPping of high Temperature Alloys (Xiqian Wang)
  • Numerical Modelling of Machining CFRP (Alessandro Abena)


Research Themes

Process development and numerical simulations of advanced manufacturing technologies in particular
• Additive Manufacturing (Selective Laser melting, Direct Laser Deposition, Ceramic 3D printing, Binder Jetting 3D printing).
• Hot Isostatic Pressing
• Hybrid Manufacturing
• Net-Shape manufacturing
• Incremental Sheet Forming
• Multi Point Forming

Current and Past Research Projects

  • Multifunctional Graphene-based Flexible Absorber (The Royal Society)
  • Metal Binder Jetting of Stainless Fittings (Rolls-Royce)
  • Metal Binder Jetting of Refractory Metals (The Manufacturing Technology Centre)
  • Hybrid Manufacturing of Ni based superalloy blisk (MBDA Missile UK)
  • 3D Printing of SiAlON ceramic blased (MicroTurbo-Safran Group)
  • Research and application demonstration of key technologies for laser 3D printing of complex Conformal cooling injection moulding (Guangdong Municipal Government).
  • Smart Factory Hub (ERDF, EU)
  • Study on key forming technology and exemplary application of medical nitinol alloys (Guangdong Municipal Government).
  • Novel Integrated Fuel Reformer-Aftertreatment System for Clean and Efficient Road Vehicles (EPSRC)
  • Development of new processing route to manufacture reactive materials (BAE Systems)
  • Series production of Lightweight parts by Isostatic pressing of Metal powders to give Material and Energy Reduction (EPSRC)
  • Modular laser based additive manufacturing platform for large scale industrial applications (Horizon 2020)
  • Robotic disassembly technology as a key enabler of autonomous remanufacturing (EPSRC)
  • Functionally graded materials for a game for missile applications (MBDA Missiles)
  • Materials and processing for ultra-high temperature applications cold section (Micro Turbo)
  • Efficient manufacturing for aerospace components using additive manufacturing, net shape HIP and Investment Casting (Horizon 2020)
  • Rapid manufacturing as a key enabler for enhanced monopropellant catalyst bed design (European Space Agency)
  • Additive layer manufacturing of superelastic-Auxetic structures: experimental development and numerical modelling (Defence Science and Technology Laboratory)
  • Net shape HIPping of IN718 engine casing (EU-Clean Sky)
  • Laser based hybrid remanufacture of complex high performance parts (Caterpillar)
  • The Centre for Advanced Simulation & Modelling for Manufacturing CASIM2 (ERDF)

Other activities

  • Academic Lead for Dubai Campus
  • Director of the Advanced Manufacturing Group
  • Editorial Board (Aerospace, Cogent Journal, American Journal of Engineering and Applied Sciences)


Book chapter

  • Abena, A., Kahwash, F., Essa, K., ‘Modelling Machining of FRP Composites’ in Advances in Machining of Composite Materials: Conventional and Nonconventional Processes. Engineering Materials, Springer International Publishing AG. DOI: 10.1007/978-3-030-71438-3.
  • Hassanin, H., Bidare, P, Zweiri, Y. and Essa, K., ‘Parts Design and Process Optimization’ in Applications of Artificial Intelligence in Additive Manufacturing. IGI Global. DOI: 10.4018/978-1-7998-8516-0


  • Porous Structures, Rolls-Royce, Application number: US20190054534A1
  • Method of remanufacturing a cylinder head, Caterpillar, Application number: GB2558274A
  • Methods and Systems for Measuring Intraocular Pressure using Soundwave: US 17/476,016

Journal publications


  • Li, W., Attallah, M., Essa, K. (2022), Experimental and numerical investigations on the process quality and microstructure during induction heating assisted incremental forming of Ti-6Al-4V sheet. J of Materials Processing Technology,
  • El-sayed, M., Essa, K., Hassanin, H., (2022), Effect of runner thickness and hydrogen content on the mechanical properties of A356 alloy castings. International Journal of Metalcasting, https://doi: 10.1007/s40962-021-00753-x
  • El-sayed, M., Essa, K., Hassanin, H., (2022), Influence of bifilm defects generated during mould filling on the tensile properties of Al-Si-Mg cast alloys, Metals,
  • Alqurashi, Y., Elsherif, M., Hendi, A., Essa, K., Butt, H. (2022), Optical hydrogel detector for pH measurements. Biosensors,
  • Li, S., Wang, M., Essa, K., Gan, C., Liu, C., Attallah, M. (2022), Effect of Stoichiometry on Shape Memory Properties of Ti-Ni-Hf-Cu-Nb Shape Memory Alloys Manufactured by Suspended Droplet Alloying. Solids,
  • Bidare, P., Jiménez, A., Hassanin, H., Essa, K. (2021), Porosity, cracks, and mechanical properties of additively manufactured tooling alloys: a review. Advances in Manufacturing,
  • Yan, Z., Hassanin, H., El-Sayed, M., Eldessouky, H., Rizki, J., Djuansjah, P., Alsaleh, N., Essa, K., Ahmadein, M. (2021), Multistage Tool Path Optimisation of Single-Point Incremental Forming Process. Materials, DOI: 10.3390/ma14226794
  • Kovacev, N., Li, S., Essa, K. (2021), Effect of the preparation techniques of photopolymerizable ceramic slurry and printing parameters on the accuracy of 3D printed lattice structures. Journal of the European Ceramic Society,
  • Mehmeti, A., Lynch, D., Penchev, P., Ramos, R. M., Vincent, D., Maurath, J., Wimpenny, D., Essa K., and Dimov S. (2021), The Effect of Hot Isostatic Pressing on Surface Integrity, Microstructure and Strength of Hybrid Metal Injection Moulding, and Laser-Based Powder Bed Fusion Stainless-Steel Components. Applied Sciences,
  • Hassanin, H., Zweiri, Y., Finet, L., Essa, K., Qiu, C., Attallah, M. (2021), Laser Powder Bed Fusion of Ti-6Al-2Sn-4Zr-6Mo Alloy and Properties Prediction Using Deep Learning Approaches. Materials,
  • Careri, F., Umbrello, D., Essa, K., Attallah, M., Imbrogno, S. (2021), The effect of the heat treatments on the tool wear of hybrid Additive Manufacturing of IN718. Wear,
  • Jiménez, A., Bidare, P., Hassanin, H., Tarlochan, F., Dimov, S., Essa, K. (2021), Powder-based laser hybrid additive manufacturing of metals: a review. The International Journal of Advanced Manufacturing Technology,
  • Hassanin, H., Essa, K., Elshaer, A., Imbaby, M., H El-Mongy, H., El-Sayed, T. (2021), Micro-fabrication of ceramics: Additive manufacturing and conventional technologies. Journal of Advanced Ceramics, 10 (1): 1-27
  • Soanes, M., Essa, K., Butt, H. (2021), Testing the viability of measuring intraocular pressure using soundwaves from a smartphone. Engineering Reports,
  • Langford, T., Mohammed, A., Essa, K., Elshaer, A., Hassanin, H. (2021), 4D printing of origami structures for minimally invasive surgeries using functional scaffold. Applied Sciences,
  • Kovacev, N., Li, S., Zeraati-Rezaei, S., Hemida, H., Tsolakis, A., Essa, K. (2021), Effects of the internal structures of monolith ceramic substrates on thermal and hydraulic properties: additive manufacturing, numerical modelling and experimental testing. The International Journal of Advanced Manufacturing Technology, 112 (3): 1115-1132
  • Mehmeti, A., Penchev, P., Lynch, D., Vincent, D., Maillol, N., Maurath, J., Bajolet, J., Wimpenny, D.I. Essa, K., Dimov, S. (2020), Mechanical behaviour and interface evaluation of hybrid MIM/PBF stainless steel components. Rapid Prototyping Journal,
  •  Soanes, M., Essa, K., Butt, H. (2020), Measuring Intraocular Pressure Using Soundwaves from a Smartphone. Engineering Reports, DOI: 10.22541/au.160029059.91237540
  • El-Sayed, M., Essa, K., Ghazy, M., Hassanin, H. (2020), Design optimization of additively manufactured titanium lattice structures for biomedical implants. The International Journal of Advanced Manufacturing Technology, 9(11): 2257-2268
  • Hassanin, H., Abena, A., Elsayed, M., Essa, K. (2020), 4D printing of NiTi auxetic structure with improved ballistic performance. Micromachines,
  • Wang, X., Carter, L. N., Adkins, N. JE., Essa, K., Attallah, M.M. (2020), Novel Hybrid Manufacturing Process of CM247LC and Multi-Material Blisks. Micromachines,
  • Cheng, K., Xiong, W., Li, Y., Hao, L., Yan, C., Li, Z., Liu, Z., Wang, Y., Essa, K., Lee, L., Gong, X., Peijs, T. (2020), In-situ deposition of three-dimensional graphene on selective laser melted copper scaffolds for high performance applications. Composites Part A: Applied Science and Manufacturing,
  • Hassanin, H., Alkendi, Y., Elsayed, M., Essa, K., Zweiri, Y. (2020), Controlling the properties of additively manufactured cellular structures using machine learning approaches. Advanced Engineering Materials,
  • Moheen, M., Abdel-Wahab, A., Hassanin, H., Essa, K. (2020), Reconfigurable Multipoint Forming Using Waffle-Type Elastic Cushion and Variable Loading Profile. Materials,
  • Bhaduri, D., Penchev, P., Dimov, S., Essa, K., Carter, L. N., Pruncu, JC. I., Jiang, J., Pullini, D. (2020), On the surface integrity of additive manufactured and post-processed AlSi10Mg parts. Procedia CIRP, 87 (2020): 339-344
  • Li, Y., Feng, Z., Hao, L., Huang, L., Xin, C., Wang, Y., Bilotti, E., Essa, K., Zhang, H., Li, Z., Yan, F., Peijs, T. (2020), A Review on Functionally Graded Materials and Structures via Additive Manufacturing: From Multi‐Scale Design to Versatile Functional Properties. Advanced Materials Technologies,
  • Careri, F., Imbrogno, S., Attallah, M. M., Essa, K., Umbrello, D. (2020), Finite Element Modeling of Machining Nickel Superalloy Produced by Direct Energy Deposition Process. Procedia Manufacturing, 47 (2020), 525-529.
  • Abena, A., Aristizabal, M. and Essa, K. (2019), Comprehensive numerical modelling of the hot isostatic pressing of Ti-6Al-4V powder: From filling to consolidation, Advanced Powder Technology, DOI:
  • Li, Y., Feng, Z., Huang, L., Essa, K., Bilotti, E., Zhang, H., Peijs, T., Hao, L. (2019), Additive manufacturing high performance graphene-based composites: A review, Composites Part A: Applied Science and Manufacturing, DOI:
  • Aldhufairi, H., Olatunbosun, O., Essa, K. (2019), Determination of a Tyre's Rolling Resistance Using Parallel Rheological Framework, SAE Technical Paper 2019-01-5069, 2019, doi:10.4271/2019-01-5069
  • Elghawail, A., Pham, D., Huang, J., Su, S., Kerin, M., Ji, C., Abosaf, M., Essa, K. (2019) Measurement of Forces on Multi-Point Forming Tools Using Fibre Bragg Grating Sensors, Journal of Engineering Manufacture, DOI:
  • Abena, A., Essa, K. (2019), 3D micro-mechanical modelling of orthogonal cutting of UD-CFRP using smoothed particle hydrodynamics and finite element methods, Composite Structures, 2018 (15 June 2019), 174-192
  • MacDonald, J, Khan, R, Aristizabal, M., Essa, K., Lunt, M., Attallah, M. (2019), Influence of powder characteristics on the microstructure and mechanical properties of HIPped CM247LC Ni superalloy, Materials and Design,
  • Tan, C., Li, S., Essa, K., Jamshidi, P., Zhou, K., Ma, W., Attallah, M. (2019), Laser Powder Bed Fusion of Ti-rich TiNi lattice structures: Process optimisation, geometrical integrity, and phase transformations, International Journal of Machine Tools and Manufacture, 141 (June 2019), 19-29
  • Bhaduri, D., Penchev, P., Essa, K., Dimov, S., Carter, N., Pruncu, C., Pullini, D. (2019), Evaluation of surface/interface quality, microstructure and mechanical properties of hybrid additive-subtractive aluminium parts, CIRP Annals,
  • Penchev, P., Bhaduri, D., Carter, N., Mehmeti, A., Essa, K., Dimov, S., Adkins, N., Maillol, N., Bajolet, J., Maurath, J., Jurdeczka, U. (2019), System-level integration tools for laser-based powder bed fusion enabled process chains, Journal of Manufacturing Systems, 50 (January 2019), 87-102
  • Aldhufairi, H., Essa, K., Olatunbosun, O. (2019), Multi-Chamber Tire Concept for Low Rolling-Resistance, SAE International Journal of Passenger Cars - Electronic and Electrical Systems, 12 (2), 8 April 2019.
  • Tolipov, A., Elghawail, A., Abosaf, M., Pham, D., Hassanin, H., Essa, K. (2019), Multipoint forming using mesh-type elastic cushion: modelling and experimentation, International Journal of Advanced Manufacturing Technology,
  • Aldhufairi, H., Essa, K., (2018), Tire rolling-resistance computation based on material viscoelasticity representation, Advances in Automotive Engineering, 1 (2), 167-183
  • Aldhufairi, H., Olatunbosun, Essa, K.  (2019), Multi-chamber tyre designing for fuel economy, Proceedings of the Institution of Mechanical Engineers Part D Journal of Automobile Engineering, Accepted and in Press
  • Elghawail, A., Essa, K., Abosaf, M., Tolipov, A., Su, S., Pham, D. (2019), Low-cost metal-forming process using an elastic punch and a reconfigurable multi-pin die. International Journal of Material Forming,
  • El-Sayed, M., Ghazy, M., Yehia, Y., Essa, K. (2019), Optimization of SLM Process Parameters for Ti6Al4V Medical Implants. Rapid Prototyping Journal, 25 (3), 433-447
  • Hassanin, H., El-Sayed, M., ElShaer, A., Essa, K., Jiang, K. (2018), Microfabrication of net shape zirconia/alumina nanocomposite micro parts. Nanomaterials, 8(8), 593-603
  • Essa, K., Sabouri, A., Butt, H., Basuny, F., Ghazy, M., El-Sayed, M. (2018), Laser additive manufacturing of 3D meshes for optical applications. PLoS ONE, journal.pone.0192389
  • Essa, K., Jamshidi, M., Zou, J., Attallah, M., Hassanin, H. (2018), Porosity control in 316L stainless steel using cold and hot isostatic pressing, Materials & Design, 138, 21-29.
  • Hassanin, H., A Al-Kinani, A., ElShaer, M., Polycarpou, E., El-Sayed, M., Essa, K. (2017), Stainless steel with tailored porosity using canister-free hot isostatic pressing for improved osseointegration implants, Journal of Materials Chemistry B, DOI: 10.1039/C7TB02444D.
  • Abosaf, M., Essa, K., Alghawail, A., Tolipov, A., Su, S., Pham, D., (2017), Optimisation of multi-point forming process parameters, The International Journal of Advanced Manufacturing Technology, DOI: 10.1007/s00170-017-0155-y
  • Hergueta, C., Bogarra, M., Tsolakis, T., Essa, K., Herreros, J. (2017), Butanol-gasoline blend and exhaust gas recirculation, impact on GDI engine emissions, Fuel, 208, 662-672.
  • Alghawail, A., Essa, K., Abosaf, M., Tolipov, A., Su, S., Pham, D., (2017), Prediction of springback in multi-point forming, Cogent Engineering, 4(1), 1-15.
  • Essa, K., Hassanin, H., Attallah, M.M., Adkins, N., J., Musker, A., Robert, G., Tenev, N., Smith, M., (2017) Development And Testing of An Additive Manufactured Monolithic Catalyst Bed For HTP Thruster Applications. Applied Catalysis A: General, 542(2017), 125-135.
  • Tolipov, A., Essa, K., Alghawail, A., Abosaf, M., Su, S., Pham, D., (2017), Experimental research and numerical optimisation of multi-point sheet metal forming implementation using a solid elastic cushion system, Journal of Physics Conference Series, DOI: 10.1088/1742-6596/896/1/012120.
  • Abena, A., Soo, S. L., Essa, K. 2017, Modelling the orthogonal cutting of UD-CFRP composites: Development of a novel cohesive zone model. Composite Structures, 168 (May 2017) pp. 65-83.
  • Sabouri, A., Yetisen, A. K., Sadigzade, R., Hassanin, H., Essa, K., Butt, H. 2017,  Three-Dimensional Microstructured Lattices for Oil Sensing. Energy & Fuels, 31(3) pp.2524-2529.
  • Abosaf, M., Essa, K., Alghawail, A., Tolipov, A., Su, S., Pham, D. T. 2017,  Optimisation of Multi-Point Forming Process Parameters. The International Journal of Advanced Manufacturing Technology, DOI: 10.1007/s00170-017-0155-y.
  • Hassanin, H., Essa, K., Qiu, C., Adbelhafeez, A., Adkins, N.J.E., Attallah, M.M. 2017, Net-Shape Manufacturing using Hybrid Selective Laser Melting/Hot Isostatic Pressing. The Rapid Prototyping Journal. 23 (4) pp. 1-8.
  • Essa, K., Modica, F., Imbaby, M., El-Sayed, M. A., Elshaer, A., Jiang, K. and Hassanin, H. 2016, Manufacturing of metallic micro components using hybrid soft lithography and micro electrical discharge machining. The International Journal of Advanced Manufacturing Technology. DOI: 10.1007/s00170-016-9655-4.
  • Hassanin, H., Essa, K., El-Sayed M.A. and Attallah, M.M. 2016, Enhancement of Student Learning and Feedback of Large Group Engineering Lectures Using Audience Response Systems. Journal of Materials Education (JME). 38(5-6) pp. 175-190.
  • Hassanin, H., Modica, F., El-Ssayed, M. A., Liu, J., Essa, K. 2016, Manufacturing of Titanium Micro-Implantable Parts using Hybrid Selective Laser Melting and Micro Electrical Discharge Machining. Advanced Engineering Materials. 18(9) pp. 1544-1549.
  • Li, S., Hassanin, H., Attallah, M.M., Adkins, N.J.E., and Essa, K. 2016, The development of TiNi-based negative Poisson's ratio structure using selective laser melting. Acta Materialia. 105(2016): p. 75-83.
  • El-Sayed M.A., Hassanin H., and Essa K. 2016, Bifilm defects and porosity in Al cast alloys. The International Journal of Advanced Manufacturing Technology. 86(5-8) pp. 1173-1179.
  • Ahmed, R., Rifat, A. A., Sabouri, A., Al-Qattan, B., Essa, K., Butt, H. 2016, Multimode waveguide based directional coupler. Optics Communications. 370(2016) pp.183-191.
  • El-Sayed M.A., Hassanin H., and Essa, K. 2015, Effect of casting practice on the reliability of Al cast alloys. The International Journal of Cast Metals Research (DOI:10.1080/13640461.2016.1145966)
  • Essa, K., Khan, R., Hassanin, H., Attallah, M.M. and Reed, R.C., 2015. An iterative approach of hot isostatic pressing tooling design for net-shape IN718 superalloy parts. The International Journal of Advanced Manufacturing Technology. 83 (9) pp. 1835-1845.
  • Qiu, C., Adkins, N. J.E., Hassanin, H., Attallaha M. M. and Essa, K., 2015 In-situ shelling via selective laser melting: Modelling and microstructural characterization. Materials and Design 87, 845-853.
  • Read, N., Wang, W., Essa, K. and Attallah, M., 2015. Selective laser melting of AlSi10Mg alloy: Process Optimisation and Mechanical Properties Development. Materials and Design 65, 417-424.
  • Carter, L., Wang, W., Read, N., Khan, R., Aristizabal, M. Essa, K. and Attallah M.M., 2015. Process Optimisation of Selective Laser Melting using Energy Density Model for Nickel based Superalloys. Materials Science and Technology. 32(7) pp.657-661.
  • Carter, L., Essa, K. and Attallah, M.M., 2013. Selective Laser Melting Fabrication of the Nickel Base Superalloy CMSX486: Optimisation of Process Parameters using Image Analysis and Statistical Methods. Rapid Prototyping Journal, 21(4):423-432.
  • Essa, K., Kacmarcik, Hartley, P., I., Plancak, M. and Vilotic, D., 2012. Upsetting of bi-metallic ring billets. Journal of Materials Processing Technology, 212(4): pp.817-824.
  • Hartley, P.;Plancak, M.;Essa, K.;Vilotic, D.;Movrin, D., 2012. Deformation analysis during bi-metallic coining operations. Steel research international journal. SPL(2012) pp.1247-1250.
  • Essa, K. and Hartley, P., 2010. An evaluation of shear deformation mechanisms in single point incremental forming using a dual-level finite-element model. Computer Methods in Materials Science CMMS, 12(1): pp.37-50.
  • Essa, K. and Hartley, P., 2010. Investigation on the effects of process parameters on the through-thickness shear strain in single point incremental forming using dual level FE modelling and statistical analysis. Computer Methods in Materials Science CMMS. 10(4): pp. 1-11.
  • Essa, K. and Hartley, P., 2010. An assessment of various process strategies for improving precision in single point incremental forming. International Journal of Material Forming. 4(4) pp. 401-412.
  • Essa, K. and Hartley, P., 2010. Optimization of conventional spinning process parameters by means of numerical simulation and statistical analysis. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 224(11): pp. 1691-1705.
  • Essa, K. and Hartley, P., 2009. Numerical simulation of single and dual pass conventional spinning processes. International Journal of Material Forming. 2(4): pp. 271-281.

Essa, K. and Hartley, P., 2009. Numerical Investigation on the Effect of Roller-Trace in Dual Pass Cup Spinning. Journal for Technology of Plasticity. 34(2009): pp. 15-25.

Conference publications

  • Bidare, P., Abdullah, R., Jiménez, A;, Essa, K., (2022) Powder Reusability in Metal Binder Jetting Process, 1st International Conference on Engineering and Manufacturing EM2022, FEUP, Porto – Portugal.
  • De Lisi, M., Kovacev, N., Attia, U., Essa, K., (2021), Numerical simulation of sintering of DLP printed alumina ceramics. ASTM International Conference on Additive Manufacturing,  Anaheim, CA, USA.
  • Careri, F., Imbrogno, S., Attallah, M. M., Essa, K., Umbrello, D. (2020), Finite Element Modeling of Machining Nickel Superalloy Produced by Direct Energy Deposition Process. 23rd International Conference on Material Forming, virtual ESAFORM.
  • Bidare, P., Bitharas, I., Ward, M., Attallah, M., Essa, K., Moore, A., (2020). Effect of Different Shield Environment on Laser Powder Bed Fusion. ILAS2020 conference, UK
  • Sergi, A., Abena, A., Khan, R., Essa, K., Attallah, M., (2019), The Influence of Atomisation route and Powder Characteristics on the Microstructural and Mechanical Properties Development of HIPped IN625 Ni-Superalloy, MS&T, USA
  • Essa, K., (2018) Advanced Manufacturing Routes for Netshape Manufacturing, 4th International Conference on Advances In Mechanical Engineering, Istanbul, December 2018.
  • Essa, K., (2018), Advances in High Value Manufacturing, Newton Utafiti Researchers Link Workshop, Nairobi, Kenya, September 2018
  • D. Bhaduri, P. Penchev, L.N. Carter, K. Essa, S. Dimov, N.J.E. Adkins, J.  Bajolet, A. Tommasi, D. Pullini, U. Jurdeczka (2018) Development and evaluation of a hybrid additive-subtractive process chain, CIRP Winter Meeting, STC 'E', Paris, France.
  • Abena, A., Segarra, M., Essa, K. (2017). Prediction of the influence of non-homogeneous powder distribution on hot isostatically pressed components combining discrete element method and finite element analysis. HIP17 - 12th International conference on Hot Isostatic Pressing, 5-8 December 2017 Sydney, Australia.
  • Abosaf, M., Elghwail, A., Pham, D., Essa, K., Tolipov, A., Su, S. (2017). Effect of overhang between die and blank holder on thickness distribution in multi-point forming. 39th International MATADOR Conference on Advanced Manufacturing, At University of Manchester, UK.
  • Thomas-Seale, L., Kanagalingam, S., Shaw, D., Triantaphyllou, A., Essa, K., Kirkman-Brown, J., Attallah, M., Espino, D., Shepherd, D. (2017). Multiscale Design for the Additive Manufacture of Medical Devices. 23rd Congress of the European Society of Biomechanics, July 2 - 5, 2017, Seville, Spain.
  • Tolipov, A., Abosaf, M., Elghwail, A., Su, S.,  Pham, D., Essa, K., (2017). Experimental research and numerical optimisation of multi-point sheet metal forming implementation using a solid elastic cushion system. 36th IDDRG-2017, At Technical University of Munich in Germany.
  • El-Sayed, M., Essa, K. (2017). Effect Of Mould Type And Solidification Time On Bifilm Defects And Mechanical Properties Of Al-7Si-0.3Mg Alloy Castings. 18th International Conference on Computational Methods and Experimental Measurements (CMEM 2017), At Alicante, Spain.
  • Essa, K., Hassanin, H., Adkins, N. J., Attallah, M. M., Roberts, G., Musker, A. and Smith M., 2015. Additive Manufacturing of Monolithic Catalyst Beds for Hydrogen Peroxide Monopropellant Thrusters. 5th CEAS Air & Space Conference. 7-11 Sept 2015 Delft University of Technology, Netherlands.
  • Adbelhafeez, A., Essa, K., Attallah, M. An investigation on the effect of powder constitutive model on the finite element simulation of hot isostatic pressing. 15th CIRP Conference on Modelling of Machining Operations 2016.
  • Essa, K., Adbelhafeez, A., Attallah, M. FEA of Hot Isostatic Pressing of Steel 316: A comparative study of different powder compaction constitutive models. Materials Science & Technology 2016. Salt Lake City, UT, USA.
  • Attallah, M., Hassanin, H., Essa, K., Li, S, Adkins, N. Additive Manufacturing of Shape Memory, Superelastic Alloys and Multifunctional Materials. Materials Science & Technology 2016. Salt Lake City, UT, USA.
  • Adkins, N., Carter, L., Qiu, C., Essa, K. Attallah, M. Selective Laser Melting of components with thick section through in-situ shelling. Materials Science & Technology 2016. Salt Lake City, UT, USA.
  • Attallah, M., Qiu, C., Essa, K., Ward, M. Scaling-up from the Laboratory: Strategies, Examples, Challenges, and/or Solutions for Advanced Metal Manufacturing. Materials Science & Technology 2016. Salt Lake City, UT, USA.
  • Hassanin, H., Essa, K., Adkins, N. J., Attallah, M. M., Roberts, G., Musker, A. and Smith M., 2015. Additive Manufacturing of Monolithic Catalyst Beds for Hydrogen Peroxide Monopropellant Thrusters. 5th CEAS Air & Space Conference. 7-11 Sept 2015 Delft University of Technology, Netherlands.
  • Abena, A., Soo, S. L. and Essa, K. A finite element simulation for orthogonal cutting of UD-CFRP incorporating a novel fibre - matrix interface model. 15th CIRP Conference on Modelling of Machining Operations. 11-12 June, 2015; Karlsruhe, Germany.
  • Attallah, M. M., Parimi, L., Essa, K. and Gebelin, J-C. Modelling the Thermal History And Residual Stress Development during Direct Laser Fabrication of Inconel 718. Materials Science &Technology. 04-08 October, 2015; Columbus, OH, USA.
  • Qiu, C., Adkins, N. J., Hassanin, H., Essa, K. and Attallah, M., M., In-Situ Shelling via Selective Laser Melting: Microstructural Characterisation and Modelling.  TMS2015 144th Annual Meeting & Exhibition; 15–19 March, 2015; Orlando, FL (USA)
  • Essa, K., Li, S., Hassanin, H., Adkins, N. and Attallah, M., 2014. Selective Laser Melting of TiNi Shape Memory Alloys: Microstructural and Structural Integrity Development. Materials Science & Technology 2014. Pittsburgh, USA.
  • Hassanin, H., Attallah, M. and Essa, K., 2014. Porosity control of stainless steel 316L parts manufactured using capsule free hot isostatic pressing. 11th In international Conference on Hot Isostatic Pressing, Stockholm, Sweden.
  • Essa, K. et al. 2014. Net Shape HIPping components of IN718. 11th In international Conference on Hot Isostatic Pressing, Stockholm, Sweden.
  • Elliott, S. M., Attallah, M. M., Cooke, K., Essa, K., Ievlev, D., Simkin, J. and White, E. K. Simulation of the Erosion Groove and Vapor Distribution of a Linear Magnetron Sputtering Cathode. SVC - 56th Annual Technical Conference Proceedings, April 20–25, 2013; Providence, USA.
  • Hartley, P.;Plancak, M.;Essa, K.;Vilotic, D.;Movrin, D., 2012. Deformation analysis during bi-metallic coining operations. Proceedings of the 14th International Conference on Metal Forming.
  • Essa, K., 2009. Investigation of the forward tube spinning process by numerical simulation. BlueBEAR user forum, University of Birmingham.

Teaching-related publications

  • Hassanin, H., Attallah, M. M. and Essa, K. Effectiveness of Clickers on Student Learning of Large Group Manufacturing Lectures. IEEE EDUCON. 17-20 March, 2015; Tallinn University of Technology, Estonia.
  • Hassanin, H. and Essa, K. Exploring the Potential of Enquiry-Based Learning in A Process Modelling Course. International Conference on Engineering and Product Design Education. 3-4 September, 2015; Loughborough University, UK.

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