# Mostafa Mahdavi, Ph.D.

> Product Design Engineer at Apple

Location: Cupertino, California, United States
Profile: https://flows.cv/mostafa

• Developed 3D CAD models and specified fabrication processes among various manufacturingtechniques, including injection molding, die casting, sheet metal forming, stamping, CNC machining,and additive manufacturing for precision component production based on functional requirements.
• Designed and fabricated over 30 functional prototypes using a combination of CNC machining, 3Dprinting, and injection molding, accelerating concept validation by 40% and saving over $600,000.
• Led the design and development of the prototyping phase of a consumer electronics device,reducing cycle time from concept to test-ready model by 35% through cross-functionalcollaboration and rapid iteration and performance testing.
• Conducted statistical tolerance and GD&T analysis across multi-material assemblies to improve reliability and assembly yield from 85% to 98% in pilot runs.
• Implemented material-level DFM/DFA improvements in collaboration with vendors and providedguidance, cutting rework time by 20% during pre-production.
• Designed in-situ bending SEM fixture to track the crack nucleation and propagation at the micro level.
• Investigated the failure behavior of 6xxx Al alloys using in-situ bending SEM and successfullycaptured the initial crack nucleation sites with the SEM, which answered valuable questions.

## Work Experience
### Product Design (PD) Engineer @ Apple
Jan 2025 – Present | Cupertino, CA

### Senior Engineer @ Nikon Research Corporation of America
Jan 2022 – Jan 2025 | San Francisco Bay Area

### R&D Automotive @ Novelis
Jan 2021 – Jan 2021 | United States

### Graduate Research Assistant @ Georgia Institute of Technology
Jan 2017 – Jan 2021 | Atlanta Metropolitan Area
• Developed complex 3D CAD models for additive manufacturing (AM) processes to reduce the
number of overall parts while maintaining strength and performance.
• Conducted in-depth Finite Element Analysis (FEA) of AM parts to modify the design while ensuring the printability of the part by implementing various Design of Experiments (DOE) techniques.
• Extracted and analyzed statistical data from the in-situ monitoring systems of the AM printers to
improve the 3D CAD models based on the part thermal distribution and final part distortion.
• Developed a model to predict the deformation behavior of additively manufactured parts in Python.
• Developed a quantitative model to predict the microstructures of SLM parts in Python.
• Worked on microstructure characterization of AM parts using a combination of TEM, EDS, SEM,
EBSD, and XRD analysis techniques for different material systems.
• Extracted statistical information from the segmented SEM images, including two-point correlation
functions, pair correlation functions, and cord-length correlation functions in MATLAB.
• Used the statistical information to build the process parameter-structure-property linkage using ML.

### Graduate Research Assistant @ University of Tehran
Jan 2013 – Jan 2016 | Tehran Province, Iran


## Education
### Doctor of Philosophy - PhD in Materials Engineering
Georgia Institute of Technology

### Master of Science (MS) in Mechanical Engineering
University of Tehran

### Bachelor of Science (BS) in Mechanical Engineering
Ferdowsi University of Mashhad

### Doctor of Philosophy - PhD in Materials Engineering
Georgia Institute of Technology


## Contact & Social
- LinkedIn: https://linkedin.com/in/mostafa-mahdavi

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Source: https://flows.cv/mostafa
JSON Resume: https://flows.cv/mostafa/resume.json
Last updated: 2026-04-13