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Abishek Kafle

Abishek Kafle

PhD Candidate · University of Houston, USA

kafleabishek (at) gmail (dot) com

CV

About Me

I'm a PhD researcher in Mechanical Engineering at the University of Houston, working at the intersection of additive manufacturing, robotics, and machine learning. My current work focuses on Cold Spray Additive Manufacturing (CSAM) for the repair and remanufacturing of metal components, paired with robotic automation and ML-based simulators (including LLMs) to make deposition planning faster and more adaptive. I hold a Bachelor's and a Master's by Research in Mechanical Engineering from Kathmandu University, with prior research on Francis-turbine manufacturing, 3D scanning, and healthcare-technology innovation in Nepal.

Abishek at sunset, Lake Travis
Location
Houston, TX
Affiliation
Univ. of Houston
Program
PhD, Mech. Eng.
Status
Open to collab.

Research Interests

Cold Spray AM
Repair & remanufacturing of metal components via supersonic particle deposition.
ML-based Simulators
Surrogate models & LLMs for faster, adaptive deposition planning.
Robotics & Automation
Manipulation, grippers, and harvesting systems for unstructured environments.
Rotating Francis runner

Experience Timeline

Aug 2023 — Present

Research Assistant

University of Houston

Houston, TX · USA

Cold Spray 3D-printing for repair & remanufacturing of metal components. Designing harvesting systems for floating aquatic plants; building robotic and ML pipelines for deposition planning.

Jul 2022 — Dec 2023

Research Associate

Kathmandu University

Dhulikhel · Nepal

Led innovation projects in healthcare technology, including prosthetics & assistive devices through the One Student One Hand initiative.

Dec 2019 — Present

Visiting Faculty

Kathmandu University

Mechanical Engineering · Part-time

Course instructor for Engineering Drawing (EDRG 101) and Elements of Engineering (ENGG 111) for undergraduate mechanical students.

Mar 2019 — Jun 2022

Research Assistant

Kathmandu University

3D Printing · Scanning · Turbines

Developed procedures for manufacturing Francis turbines in Nepal — combining 3D printing, scanning, investment casting, and control systems.

Sep — Dec 2018

R&D Engineer

Orion Space

PocketQube Structural Sub-system

Development & analysis of the structural sub-system of Nepal PQ1 — a miniaturized student satellite.

Jun — Aug 2018

Intern

SunFarmer Nepal

Solar & Water Pumping

Product development, commissioning & troubleshooting of solar water-pumping systems and on-grid solar deployments.

Awards & Recognition

2016

Best Project Presentation — AVIYANTAA

Microcontroller-based color-sensing & wire-cutting robot.

2016

2nd Runner-up — KU Startup Weekend

IoT-based Smart Agriculture System.

2016

3rd Runner-up — IOE ROBOCON

National-level robotics competition, Nepal.

Certifications

Apr 2025

UR20/30 e-learning

Universal Robots — collaborative robot programming & safety.

Mar 2025

Certified SOLIDWORKS Professional (CSWP)

Tangix Design & Development AB · Credential C-M3HCUZLPNE.

Jan 2020

3D Printing Applications

Coursera · Credential W6NTMP658NP5.

Jan 2020

Programming for Everybody — Python

Coursera · Credential 2G2XJEUZYCK5.

Publications

Filter
16 of 16 publications · All topics
Cold Spray AM
Bonding · Stress · 2025
Material Behavior in Cold Spray Additive Manufacturing: Bonding Mechanisms, Stress Analysis, and Microstructural Development
A. Kafle, K. T. Baker, R. Silwal, S. Lu, W. Zhu
ASME IMECE 2025 · 89336, V002T03A083
Cold Spray AM
Materials Review · 2025
Advancements in Cold Spray Additive Manufacturing: A Review of Materials and Processes
A. Kafle, R. Silwal, B. Koirala, S. Lu, W. Zhu
IISE Annual Conf. Proc., 1–6 · 2025
Material Dynamics
CSAM · 2025
A Review on Material Dynamics in Cold Spray Additive Manufacturing: Bonding, Stress, and Structural Evolution in Metals
A. Kafle, S. Lu, R. Silwal, W. Zhu
Metals 15, 187 · 2025
Floating Treatment
Wetlands · 2025
The Bioremediation of Nutrients and Heavy Metals in Watersheds: The Role of Floating Treatment Wetlands
N. Kumar, B. Singh, Y. Chen, A. Kafle, W. Zhu, R. L. Ray, S. Kumar, X. Shan, V. Balan
Applied Sciences 15, 9896 · 2025
CSAM Review
Process & Optimization · 2024
Advancements in Cold Spray Additive Manufacturing: Process, Materials, Optimization, Applications, and Challenges
A. Kafle, R. Silwal, B. Koirala, W. Zhu
Materials 17, 5431 · 2024
Robotic Mushroom
Harvesting · 2024
Robotic Button Mushroom Harvesting Systems: A Review of Design, Mechanism, and Future Directions
B. Koirala, A. Zakeri, J. Kang, A. Kafle, V. Balan, F. A. Merchant, D. Benhaddou, W. Zhu
Applied Sciences 14, 9229 · 2024
Three-Finger
Gripper · 2024
A Hybrid Three-Finger Gripper for Automated Harvesting of Button Mushrooms
B. Koirala, A. Kafle, H. C. Nguyen, J. Kang, A. Zakeri, V. Balan, F. Merchant, D. Benhaddou, W. Zhu
Actuators 13, 287 · 2024
ML Fault Detection
Pumps · 2023
Application of Machine Learning Algorithm for Fault Detection in Pump
A. Bhattarai, A. Gupta, A. Kafle, P. Sapkota, S. Chitrakar, O. G. Dahlhaug, S. Pradhan
EPEN 2023, Springer · 235–247
Energy Storage
Review · 2023
A Review on Energy Storage Systems
P. Tiwari, A. Kafle, P. Bijukchhe, A. Bhattarai
J. Phys.: Conf. Ser. 2629, 012024 · 2023
Casting Parameters
750 kW Runner · 2022
Determination of Casting Parameters for Affirmative Directional Solidification in 750 kW Francis Runner
A. Kafle, N. Sapkota, R. Silwal, P. L. Shrestha, N. Sharma, B. Thapa
IOP Conf. Ser. EES 1037, 012010 · 2022
CNN Vibration
Hydropower · 2022
Vibration Analysis of 3D-Printed Runner with CNN for Hydropower Condition Monitoring
R. Silwal, A. Kafle, P. Sapkota, P. L. Shrestha, O. G. Dahlhaug, B. Thapa
IOP Conf. Ser. EES 1037, 012054 · 2022
3D-Printed
Francis Runner · 2022
Use of 3D Printing Technology for Developing a Novel Procedure to Manufacture Runner of Francis Turbine
A. Kafle, P. L. Shrestha, R. Silwal, B. Thapa, A. Ghimire, S. Chitrakar
IOP Conf. Ser. EES 1037, 012012 · 2022
3D/4D Printing
Polymers · 2021 · most-cited
3D/4D Printing of Polymers: Fused Deposition Modelling (FDM), Selective Laser Sintering (SLS), and Stereolithography (SLA)
A. Kafle, E. Luis, R. Silwal, H. M. Pan, P. L. Shrestha, A. K. Bastola
Polymers 13, 3101 · 2021 · most-cited
Casting Tech
Hydro Turbines · 2020
A Review on Casting Technology with the Prospects on Its Application for Hydro Turbines
A. Kafle, P. L. Shrestha, S. Chitrakar, B. Thapa, B. S. Thapa, N. Sharma
J. Phys.: Conf. Ser. 1608, 012015 · 2020
Brass Francis
Turbine · 2020
Investigation of Mechanical Properties of Brass Francis Turbine Manufactured by Local Investment Casting Technique in Nepal
S. Kattel, J. P. Bhatt, R. Subedi, B. Thapa, S. Sujakhu, A. Kafle, T. M. Shakya
J. Phys.: Conf. Ser. 1608, 012013 · 2020
Francis Turbine
Mfg. in Nepal · 2020
Francis Turbine: Manufacturing in the Context of Nepal
R. R. Mainali, S. Adhikari, A. Kafle, P. L. Shrestha
J. Phys.: Conf. Ser. · CRHT X · 2020

Selected Works

Cast Francis turbine runner
Cast Francis Runner
Manufacturing · 2022
3D printed Francis runner
3D-Printed Francis Runner
CSAM · 2022
Investment casting at workshop
Investment Casting
Field · 2022
3D printed prosthetic foot
Prosthetic Foot Prototype
Healthcare · 2023
Design Lab Data Logger v2
Design Lab Logger v2
Electronics · 2021
Load cell weighing rig
Load-Cell Test Rig
Instrumentation · 2021
3D scanned bust
3D-Scanned Bust
Reverse Engineering · 2021

Videos

Talks, demos, and short clips from my research and projects.

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Introduction to Digital Manufacturing & Design

Webinar · Fewa Academy

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Procedures for Manufacturing Francis Turbine Runner in Nepal

Project walkthrough

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Manufacturing of Francis Turbine — IAHR Asia 2021

Conference presentation

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Project feature

YouTube

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Project feature

YouTube

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Project feature

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Project feature

YouTube

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