Ahmed A Hassen

Ahmed A Hassen

Group Leader & Senior R&D Staff Scientist

Dr. Hassen is the Group Leader for the Composites Innovation (CI) Group in the Manufacturing Science Division (MSD) at Oak Ridge National Laboratory (ORNL). He is leading ORNL's development efforts in high-rate manufacturing of advanced composites structures. Ahmed is leading ORNL’s molds and dies manufacturing portfolio for the composite manufacturing industry. One of his leading efforts is to develop a vision and strategies for smart manufacturing of polymers and advanced composites aiming to advance the U.S. competitiveness in the global market of manufacturing. Dr. Hassen contributed to the creation of a new market for Additive Manufacturing (AM) technologies by developing a new class of composite feedstock materials for large-scale AM systems. He has expertise in a wide variety of composite manufacturing, characterization, and qualification methods and he is currently leading/managing several technical research efforts with a large funding portfolio in this field. Dr. Hassen is mentoring, supporting, and managing a group of undergraduate and graduate students (PhD and Masters), postdoctoral fellows, and junior/senior staffs. Dr. Hassen was serving on the Board of Directors (BOD) of the American Society for Non-destructive Testing (ASNT) and was the Chairman of the ASNT Research Symposium (2020-2022). He has published 90+ articles in high impact journals and proceedings, holds several patents, has received three R&D 100 Awards, named the 2021 Society of Manufacturing Engineers (SME), Jud Hall Composites Manufacturing Award recipient in addition to multiple honors and technical awards.

11/2023: R&D 100 - Precise, Continuous, & High-Speed Manufacturing of Thermoplastic Composites Using Additive Manufacturing-Compression Molding (AM-CM)

10/2022: Combined Strength Award - CAMX 2022 for AMCM: Integrated Large-Scale Additive Manufacturing and Compression Molding Process

11/2021: Jud Hall Composites Manufacturing Award, Society of Manufacturing Engineers (SME)

11/2021: ORNL Innovation Awards - Method for Printing Low Density Polymer Structures

12/2020: ORNL Innovation Awards -License, Magnum Venus Products, Inc.

11/2019: American Society for Non-destructive Testing (ASNT) Young NDT Professional Award and Recognition

09/2019: Outstanding Technical Paper Award for technical paper "Replacing metal-based lightning strike protection layer of CFRPs by 3D printed electrically conductive layers" in the category of "Best in Track: Advances in Materials" in the CAMX 2019 conference, Anaheim, CA, USA

11/2018: ACMA’s Awards for Composites Excellence (ACE) Manufacturing Category, Developing of Large Scale AM System for Reactive Polymers

11/2017: R&D 100 - Coating Solutions for Large-Format Additive Manufacturing

11/2017: R&D 100 - Techmer Engineered Additive Manufacturing Materials (TEAMM)

10/2016: ACMA’s Awards for Composites Excellence (ACE) Manufacturing Category, Materials and Process Innovation Award 3D Printing of High Temperature Thermoplastic Molds

08/2016: Guinness World Record Certificate for “The largest solid 3D printed item”

Ph.D. in Material Science and Engineering, University of Alabama at Birmingham (UAB), USA 

M.Sc. in Marine and Offshore Engineering, Maritime Academy – “Arab Academy for Science, Technology, and Maritime Transport (AASTMT)”, Egypt

B.Sc. in Marine and Offshore Engineering, Maritime Academy – “Arab Academy for Science, Technology, and Maritime Transport (AASTMT)”, Egypt

2019-2022: Board of Directors (BOD) of American Society for Non-destructive Testing (ASNT)

2019-2022: Chairman, American Society for Non-destructive Testing (ASNT) – Research Symposium, major NDT conferences in the U.S.

07/2021: Co-Chair, SAMPE Additive Manufacturing Virtual Workshop

03/2021: University of Toledo & ORNL - Advanced Manufacturing for Molds and Dies of the Future (AM-MDF) – Advancing the Automotive Industry Virtual Workshop

2018-2020: Steering committee for the Society of Automotive Engineers (SAE), “Innovations in Mobility Conference”

2020-Present: Member of the Engineering Council, American Society for Non-destructive Testing (ASNT)

10/2019: Organizing the SAMPE “Tooling Technologies for Composite Manufacturing”, (First time in the East Coast) and hosting the event in ORNL/UTK 

03/2017: Co-program Chair for ASNT 26th Research Symposium, Jacksonville, FL, USA

2016-Present: Member of the financial award committee, American Society for Non-destructive Testing (ASNT)

2016-Present: Member of the Research Council Program Committee, American Society for Non-destructive Testing (ASNT)

Rapid manufacturing of tailored preforms, US2020/0023556A1.

Long fiber injection molding, US2021/0154896A1.

Increased material flow throughput in large scale additive manufacturing through movable segmented build platform, US2020/0290276A1.

System and method for additive manufacturing with toolpath bridges and resultant structure, US2020/0230888A1.

Systems and methods for generating a graded lattice structure and their application to additive manufacturing, US11602898B2.

Self-sensing of printed polymer structures, US 2020/0049648A1.

Method for printing low-density polymer structures, US2019/0338106A1.