Malaysia

Ir. Ts. Dr. Muhammad Hafiz Hassan

Senior Lecturer, School of Mechanical Engineering, Universiti Sains Malaysia (Engineering Campus, Nibong Tebal, Penang, Malaysia)
Available for international keynotes, research collaboration and doctoral supervision

Advancing aerospace manufacturing through precision hole-making. His research develops customised drill geometries and nanocomposite coatings that enable defect-free, single-shot drilling of carbon fibre and metal stacks.

Email Phone +6019-406 2175
Ir. Ts. Dr. Muhammad Hafiz Hassan in a blue suit
Professional Engineer (BEM) Professional Technologist (MBOT)
Industry, academic and professional network
MJIITMalaysia-Japan International Institute of Technology
01Research focus

Areas of research expertise

Seven interconnected research areas spanning aerospace machining, surface engineering, composite processing and community engineering. Select an area to view its research question, its significance, potential thesis directions and the methods involved.

02Fundamental research

Fundamental research

Projects funded under the Fundamental Research Grant Scheme (FRGS) of the Ministry of Higher Education Malaysia. This work investigates the underlying mechanisms that govern machining quality and material behaviour, rather than optimising outcomes alone.

A twist drill boring through a stacked CFRP and aluminium panel, the core problem in his research CFRP / AFRP composite Aluminium 7075-T6 Custom drill geometry + ta-C / DLC coating Burrs, delamination, adhesion, tool wear
Single-shot drilling of a composite–metal stack: two materials with contrasting failure modes, machined by one tool in a single pass.

Key challenges in stack drilling

  • DelaminationComposite layers peel apart at the hole entry and exit.
  • BurrsAluminium bends out at the exit instead of cutting cleanly.
  • Adhesion and tool wearHot aluminium sticks to the cutting edge and blunts it.
  • Poor hole accuracyOversize or oval holes weaken the fastened joint.

His fundamental research establishes the mechanism behind each defect and translates it into optimised drill geometries and coatings that prevent it.

FRGS · Lead researcher · RM 88,750

Mechanisms of twist-drill geometry in drilling aramid fibre and aluminium stacks

Elucidating the combined effects of twist drill geometry and cutting mechanism when drilling aramid fibre reinforced plastic (AFRP) stacked on Al 7075-T6.

  • The problemAramid fibres resist clean shearing and tend to tear rather than cut, while hot chips from the underlying aluminium layer are carried back through the composite.
  • The questionHow do point angle, helix angle and cutting-edge design alter the cutting mechanism in each layer, and which combination yields a single high-quality hole?
  • The approachCustom-ground twist drills; thrust force and surface roughness measurement; SEM characterisation of adhesion layers and tool wear; statistical optimisation.
  • The outcomePublications in the Journal of Composites Science (2025) and the International Journal of Nanoelectronics and Materials, one Master's graduate and a patent application for a machining tool bit.
September 2022 to February 2025 · final report submitted
FRGS · Co-researcher · RM 138,500

Influence of 4D-printing parameters on the shape memory behaviour of PLA

The role of 4D printing parameters on the shape memory behaviour of polylactic acid (PLA) shape memory polymer.

  • The problem3D-printed PLA can be programmed to change shape on heating and later recover it, but recovery varies considerably between prints.
  • The questionWhich printing parameters, and what level of TPU blending, govern the extent and accuracy of shape recovery?
  • The outcomeA Q1 article in Polymer Testing (2025), a Springer proceedings paper and a Master's thesis.
Led by Prof. Jamaluddin Abdullah · September 2021 to July 2025
FRGS · Co-researcher · RM 94,900

Effect of plain-weave fibre architecture in kevlar–kenaf hybrid composites

Elucidating the effect of plain weave fibre architecture of kevlar fibre reinforcement in kenaf natural composites.

  • Why it mattersKenaf, a fibre crop cultivated in Malaysia, could partially replace synthetic fibres to produce lighter and more sustainable composites.
October 2023 to March 2026
03Speaker profile

Keynote and invited speaking

An experienced international speaker who has presented, trained and served as visiting faculty in France, Spain, the United Arab Emirates, Jordan, Türkiye, India, China and Japan, as well as at Malaysian universities and schools. The topics below draw directly on his current research programme.

Open to collaboration worldwide

Seeking research partners around the world

Dr. Hafiz welcomes collaboration with universities, research institutes and industry worldwide, including joint research and grant proposals, visiting appointments, co-supervision of doctoral students, keynote invitations and industry projects in composites, machining, coatings and machine vision.

Global collaboration

Seeking research collaborators around the world

Dr. Hafiz welcomes partnerships with universities, research institutes and industry worldwide in aerospace machining, composite materials, surface coatings, machine vision and sustainable engineering. Opportunities include joint research and grant proposals, visiting appointments, student exchange and doctoral co-supervision.

FranceParis

Keynote address, International Conference on Material Science and Engineering, 2022

United Arab EmiratesDubai

Keynote addresses, 1st and 2nd World Congress on Mechanical and Mechatronics Engineering, 2018 and 2019

TürkiyeUşak

ERASMUS+ staff mobility training, Uşak University, 2022

ChinaChongqing

Oral presentation, International Conference on Climate Change: Ecosystem Resilience and Adaptation, Chongqing University, 24 to 26 April 2026

JapanTokyo · Hosei University

Organising Committee Member, ICACM 2024 and ICACM 2026. Best Presenter Award, 9th International Conference on Advanced Composite Materials, 2026

★ Best Presenter Award 2026
Drag to explore · select a country to focus on it
SpainTui, Pontevedra

In-person professional training in carbon fibre composites (resin infusion and prepreg moulding), Castro Composites, 14 to 18 July 2025

JordanAttarat Um Ghudran

Visiting lecturer, Attarat Power Company (APCO), 2024

IndiaMohali, Punjab

Invited Visiting Faculty, 16th International Faculty Exchange Program (IFEP), Chandigarh University, 28 March to 10 April 2026

MalaysiaPenang (home institution)

Universiti Sains Malaysia, with keynote talks at universities and schools nationwide

9 countries across Europe and Asia · 10 international engagements since 2018

Signature talk topics

One pass, two materials: single-shot drilling of aircraft composite–metal stacks

The case for single-shot drilling in aerospace assembly, the defects it must overcome and how customised drill geometry resolves them. Suited to manufacturing and aerospace audiences.

Diamond-like carbon and ta-C nanocoatings for tools and moving parts

Applying thin-film carbon coatings to reduce friction and wear, from cutting tools to pump components. Builds on his 2022 keynote address in Paris.

From lab to factory floor: university–industry R&D in Malaysia

Insights from consultancy with aerospace, coating and pump manufacturers, including the development of the trademarked INNOTO4COM machining tool.

Engineering for communities and the SDGs

Translating engineering research into community impact through solar drying houses, smart food-processing facilities and engineered animal habitats. Suited to outreach, education and sustainability forums.

Speaker biography

Ir. Ts. Dr. Muhammad Hafiz Hassan is a Senior Lecturer at the School of Mechanical Engineering, Universiti Sains Malaysia, and a registered Professional Engineer (BEM) and Professional Technologist (MBOT). His research centres on single-shot drilling of composite–metal stacks for aerospace structures, customised cutting-tool design and nanocomposite coatings such as ta-C and diamond-like carbon. Before joining academia he worked in the aerospace industry with Spirit AeroSystems Malaysia. He leads national research grants, including FRGS and PPRN projects, and has published more than 60 refereed works with over 870 citations.

Speaking and international engagement

    04Publications

    Publications

    Refereed journal articles, book chapters and conference proceedings published between 2013 and 2026. Filter by research area or publication type, or search by keyword, for example CFRP, coating or NiTi.

    Research area coverage by year

    Areas are ranked by total publications. Select a row to filter the list below; select it again to clear.Columns are areas ranked by total. Tap a column to filter the list; tap again to clear.

      05Research funding

      Research funding

      Competitive national, public-private and university research funding. Select a segment of the chart or a legend entry to view the associated projects.

      Grant amount by funding scheme

        Projects

        Featured project · PPRN 3.0 · Lead researcher
        Industry partnerDhabsinai Farm logoFunded byKementerian Pendidikan Tinggi (Ministry of Higher Education Malaysia)Public-Private Research Network (PPRN)

        DEHAB: an engineered basking platform for desert reptiles in a tropical climate

        Fabrication of the Dhabb Environment Heat-Activated Base (DEHAB) as a heating solution for Uromastyx aegyptia. A public-private research project between Universiti Sains Malaysia and Dhabsinai Farm, Kamunting, Perak.

        Live IoT data ↗
        Finished black carbon fibre DEHAB casing
        CFRP casing after wet layup and vacuum bagging
        Assembled DEHAB with sand under a thermal imager
        Assembled bed under thermal-imaging test
        CCTV frame of dhabbs basking on the DEHAB bed at the farm
        Field trial at Dhabsinai Farm: animals pale after basking, indicating thermal comfort
        55 mmoptimum sand thickness
        50–55 °Cstable basking surface
        +25%juvenile weight gain over four weeks
        ≈100 Wheater power at steady state
        0.6%simulation error against measurement

        Validation: measured against simulated surface temperature

        Drag the slider or press Play to step through the four-hour heating run.

        Measured thermal image
        Measured thermal camera
        Simulated thermal image
        Simulated CFD model
        0 min33 min48 min121 min189 min242 min

        Objectives

        • MetLightweight, humidity-resistant CFRP casing
        • MetFlatbed heater maintaining 50–55 °C in laboratory and field conditions
        • LiveReal-time IoT monitoring with ESP32 sensors and alerts
        • OngoingAnimal welfare and growth assessment, with positive interim results

        Budget

        RM 49,625 in total: RM 44,625 PPRN funding including the 5% administration fee, and RM 5,000 from Dhabsinai Farm.

        RM 46,812.27 of the RM 47,500 operating budget spent (98.6%), eP@USM statement of 12 October 2026.

        Outputs

        2publications2final year projects2copyrights2gold awards

        Team

        • Ir. Ts. Dr. Muhammad Hafiz HassanIr. Ts. Dr. Muhammad Hafiz HassanProject leader, CFRP casing
        • Ir. Dr. Mohd Syakirin RusdiIr. Dr. Mohd Syakirin RusdiHeat-transfer simulation
        • Dr. Muhammad Fauzinizam RazaliDr. Muhammad Fauzinizam RazaliIoT monitoring and FEA
        • Dr. Amirah HurzaidDr. Amirah HurzaidAnimal physiology and behaviour
        • Mr. Azhar Mohamed ShapawiMr. Azhar Mohamed ShapawiIndustry partner, Dhabsinai Farm

        Approved by USM IACUC (USM/IACUC/2025/(153)(1381)) and PERHILITAN (JPHLTN.600-6/1/4 JLD3 (86)).

        07Industry engagement

        Industry engagement and consultancy

        Industry partners in Malaysia and abroad engage his expertise to resolve manufacturing challenges through machine vision, laboratory testing, cutting-tool design and advanced coatings. Consultancy records are drawn from the USM HCMS academic CV for 2021 to 2025.

        International industry project · Jordan · 2024

        Machine-vision particle sizing of oil shale fuel at the Attarat power plant

        Developed during his 2024 visiting appointment with Attarat Power Company (APCO), Jordan, under the EMJ–APCO research mobility programme. The study proposes three machine-vision concepts to replace manual sieving of oil shale fuel, so that particle size distribution is reported for every batch without manual data entry and off-specification fuel is flagged before it reaches the circulating fluidised-bed boilers.

        Universiti Sains MalaysiaSchool of Mechanical EngineeringUSM logo
        Control-room CCTV wall at the plant
        Control-room CCTV wall: crusher, apron feeders and belts
        Monitor showing fuel conveyor belts
        Belts 8A and 8B carry fine fuel; 5A carries coarse lumps
        Mixed oil shale sample
        Mixed oil shale sample as received
        Proposed camera location at the feed line
        Proposed location at the chute and conveyor
        ≈1 hcurrent laboratory reporting delay
        0.1 mm/pxresolution required at the fuel
        3machine-vision design concepts
        EN 933-1sieve classes matched in the report
        2 in a rowbreaches before an alarm is raised
        A

        Top-view multi-camera workstation

        Three overhead cameras image a backlit tray of sub-sample taken from Automatic Samplers 8A and 8B.

        B

        Falling-curtain analyser

        Particles fall past a strobed backlight while two side cameras measure every particle once.

        C

        On-belt 2D and 3D sensing

        A laser profiler and camera above the conveyor monitor the entire flow continuously.

        The interactive project includes a batch simulator for each concept, an alarm and cloud notification simulator, and a digital twin that forecasts crusher liner wear. Batch runs in the project are simulated for demonstration.

        Industry problem Worn tools and poor hole quality Lab testing SEM, nanoindentation, CFD Tool and coating design drill geometry, DLC, AlCrN Solution delivered Report, prototype or training Industry problemWorn tools and poor hole qualityLab testingSEM, nanoindentation, CFDTool and coating designdrill geometry, DLC, AlCrNSolution deliveredReport, prototype or training
        Partners

        Organisations he has worked with

        Industry clients and consultancy

        International academic and training partners

        Malaysian academic partners and funders

        Professional bodies and industry experience

        R&D consultancy by company

        Industry research and development projects, excluding the Penang Port training programme detailed below.

        RM 288,000 · Penang PortProfessional Diploma in Mechanical Structure Integrity and Inspection with Lean Management (PDMSI-LM), 2023, delivered by a 12-member USM team.
        International training partner · Spain · 2025

        Castro Composites (Resinas Castro S.L.)

        In-person professional training in carbon fibre composites at the company's facilities in Tui, Pontevedra, covering mould and part production by resin infusion and prepregs, 14 to 18 July 2025.

        Advisory roles

        • 2021–23Research and Development AdvisorSurtreat Solutions Sdn Bhd
        • 2021–24Technical AdvisorGandtrack Asia Sdn Bhd
        • 2021–24Research and Development AdvisorM Pump & Engineering Sdn Bhd

        Projects and testing services

          Before academia

          • 2015–20Application Specialist, Gandtrack Asia Sdn Bhd
          • 2014–15Material and Process Engineer, Spirit AeroSystems Malaysia
          • 2011Industrial attachment, The Armour Factory Sdn Bhd
          08Teaching

          Teaching portfolio

          Undergraduate and postgraduate courses delivered at the School of Mechanical Engineering and partner schools from academic session 2020/2021 to 2026/2027, as recorded in the USM HCMS academic CV. Each course lists the sessions and semesters in which it was taught.

          Students taught by academic session

          Students taught in each session, counting each cohort once (one cohort is typically 140 to 160 students). Elective classes draw on these same cohorts. Session 2026/2027 is scheduled, so enrolment has not yet been recorded.

          Course leadership

          • 2020/21Course Coordinator, EPL212 and EPL322 Manufacturing Laboratory IFebruary to August 2021
          • 2021/22Course Coordinator, EPL331 and EPL431 Manufacturing Laboratory IISeptember 2021 to March 2022
          • 2021/22Course Coordinator, EPM212 Metrology and Quality ControlApril to August 2022
          • 2022–24Laboratory Manager, School of Mechanical EngineeringJanuary 2022 to December 2024
          • 2021–23Quality Manager, School of Mechanical EngineeringJanuary 2021 to December 2023
          LabTeaching simulators in action

          Virtual laboratories aligned with each course

          Short video demonstrations of 15 browser-based simulators developed by Dr. Hafiz, which let students rehearse machining, robotics, scanning, 3D printing, metrology and nanomechanical testing before working on the physical equipment. Select any video to watch it.

          Machining and hole making

          EPP201 Manufacturing Technology I

          1 video
          Industrial robotics and automation

          EPC451 Robotic and Smart Factory

          3 videos
          Reverse engineering and additive manufacturing

          Product Design and Development (EME462 Mechanical Product Design)

          2 videos
          Production and assembly systems

          EPM321 Manufacturing Systems

          4 videos
          Dimensional metrology

          EPM212 Metrology and Quality Control

          2 videos
          Nanoindentation and nano-scratch testing

          Materials testing and industry training

          3 videos

          Sem 1 and Sem 2 are the regular semesters; Special is the extended or intersession semester. Course codes changed in some sessions (for example EPC431 became EPC451), so related codes are grouped under one course.

          09Supervision

          Postgraduate supervision

          Master's and doctoral researchers supervised as main supervisor or co-supervisor, with thesis topics closely aligned to his funded research programme.

          Pursue a Master's or PhD in advanced manufacturing

          Prospective candidates in machining, composites and surface coatings are invited to submit a brief CV, academic transcript and a short statement identifying their research area of interest. Enquiries about current openings and Graduate Research Assistant positions on active grants are welcome.

          10Recognition

          Awards, recognition and intellectual property

          Awards

            Intellectual property

            Professional registration

            • BEMProfessional Engineer, Board of Engineers Malaysia (P123421)
            • MBOTProfessional Technologist, Malaysia Board of Technologists (PT20030016)
            • UniKLExternal Examiner, UniKL Malaysian Spanish Institute, 2024 – 2029
            Google ScholarCitations profile (opens in a new tab)ORCID0000-0002-8717-8973 (opens in a new tab)Scopus ID57216552671 (opens in a new tab)Web of Science ResearcherIDO-9321-2018 (opens in a new tab)USM ExpertsOfficial USM profile (opens in a new tab)
            11Curriculum vitae

            Infographic curriculum vitae

            A 9-page visual curriculum vitae, updated in October 2026 with all 64 refereed works, research funding, the DEHAB and APCO Jordan projects, consultancy, teaching by academic session, active and past postgraduate students, keynote speaking and intellectual property. Select a page to preview it, or download the print-ready A4 PDF.

            A4 · 9 pages · print ready

            Curriculum vitae (PDF)

            A4 · 9 pages · updated October 2026

            Email Dr. Hafiz

            Subject:

            mhafizhassan@usm.my
            Write in Gmail Write in Outlook Open my email app

            Alternative email: hssn_hfz@yahoo.com · Phone: +6019-406 2175