خالد الأنصاري

Mechanical Engineer and Senior Application Engineer with nearly five years across additive manufacturing, reverse engineering, mechanical design, quality control and R&D support. Owns the complete digital-manufacturing workflow — 3D scanning → parametric CAD with GD&T → DfAM → FDM/SLA production and EOS metal-AM build preparation → CMM (Calypso) validation. 20 months full-time at KACST's Innovation Center for Industry 4.0, followed by an industrial AM and digital-inventory program at SATORP.

Senior Application Engineer | prev. Production & Mechanical Design Engineer at Namthaja — 3D Printing & Manufacturing Solutions (2023-10 – Present)

• Designed and supported production of 220+ engineering solutions across FDM, SLA and metal-AM for industrial clients across Saudi Arabia — many under live "production is down" emergency windows.
• Sole engineer on a GASCO valve-cap development program: 9 designs, 50+ iterations, 150 PP prototypes — passed pull-strength and pressing-machine trials; advanced to pricing for a 300-piece pilot toward a 120M-piece target volume.
• Own the full delivery chain: requirement capture, 3D scanning, reverse engineering, CAD with GD&T, DfAM, slicing, build execution, inspection and handover.
• Reduced print failures by ~20% through parameter and material optimization; manage 15–25 builds/month across prototype and small-batch production.
• Advise clients on DfAM, manufacturability and material/process selection; train personnel in AM workflows, documentation and quality validation.
• Assessed a 93,453-item spare-part inventory for AM feasibility, categorizing and prioritizing candidates for the plant's digital-inventory program.
• Collected engineering data directly from plant warehouses; 3D scanned and reverse engineered ~100 selected components into production-ready CAD with GD&T.
• Identified AM opportunities with cost reductions of up to 95% in selected cases; trained on-site personnel on printers, slicing and AM workflows.

On-Site Contract - Digital Inventory & Additive Manufacturing Program at SATORP (Refining & Petrochemical) (2026-04 – 2026-08)

• Assessed a 93,453-item spare-part inventory for AM feasibility, categorizing and prioritizing candidates for the plant's digital-inventory program.
• Collected engineering data directly from plant warehouses; 3D scanned and reverse engineered ~100 selected components into production-ready CAD with GD&T.
• Identified AM opportunities with cost reductions of up to 95% in selected cases; trained on-site personnel on printers, slicing and AM workflows.

On-Site Assignment - R&D Support, Reverse Engineering & Quality Control at KACST Innovation Center (ICI4) (2024-08 – 2026-03)

• Supported 25+ R&D and innovation projects from concept and reverse engineering through prototyping, inspection and iteration — including urgent ~1-day prototypes for high-level visits.
• Reverse engineered complex components — including Lucid automotive parts — from Creaform 3D scans into parametric CAD, engineering drawings and printed prototypes.
• Led dimensional inspection with ZEISS CMM (Calypso), roughness, roundness, hardness and XRF material verification; delivered 80+ inspection reports.
• Prepared EOS M290 metal-AM builds via EOSPRINT — mesh repair, orientation, slicing, production files — alongside FDM/SLA build preparation.
• Built a revision-controlled digital parts library and trained engineers on the full scan → CAD → print → inspect workflow; supported an autonomous material-movement platform (LiDAR, ROS/SLAM).

Part-Time · Remote — CAD, FEA & Additive Manufacturing at Independent / Freelance Engineering Projects (2018-01 – Present)

• End-to-end client projects: CAD → FEA → print → documentation; built client-specific parametric configurators in OpenSCAD / Fusion 360.
• Designed maintenance solutions for life-safety systems with cross-functional teams; built 3D study models for efficiency and cost-reduction proposals.

Mechanical Engineer | Studies & Development / Operations & Maintenance at General Presidency for the Affairs of the Grand Mosque and the Prophet's Mosque (2018-01 – 2020-12)

Designed maintenance solutions for life-safety systems with cross-functional teams; built 3D study models for efficiency and cost-reduction proposals.

B.Sc. in Mechanical Engineering – Umm Al-Qura University (2012-01 – 2017-12)