ENG. RAMI KHALIL
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Eng. Rami Khalil

Expert Mechanical Design and Production Engineer
(Machinery Designer and Developer)

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Eng. RamiKhalil

Summary:

Results-driven and solutions-focused Engineering Director with 14+ years of international experience driving innovation and excellence in the oil & gas industry. Recognized as a Subject Matter Expert (SME) in mechanical design and development of downhole tools, automation systems, CNC machines, robotics, and both additive and subtractive manufacturing.

Proven leadership in managing full engineering project lifecycles—from R&D and market analysis to design, prototyping, and deployment—delivering complex, high-reliability mechanical systems that operate under extreme downhole conditions. Skilled at aligning engineering initiatives with business objectives, optimizing team performance, and ensuring full compliance with API, DS-1, ASME, ISO, and other industry standards.

Leads with a hands-on approach and a strong commitment to innovation, quality, and operational efficiency. Known for cultivating engineering talent, driving continuous improvement, and fostering collaboration across multidisciplinary teams. Brings a deep understanding of real-world constraints and technical challenges, ensuring robust, field-ready solutions for the most demanding environments.

Specializations:

  • Oil & Gas Downhole Tools & Technologies – Well Drilling, Casing, Completion Technologies.
  • Mechanical Design & Engineering – Complex Systems, High-Reliability Solutions, Mechanical Systems Development.
  • Robotics & Automation – Industrial Automation and Robots, Motion Control, Mechatronics.
  • Additive & Subtractive Manufacturing – Metal 3D Printing, Rapid Prototyping.
  • CNC Machine Design – Multi-Axis Machine, Programming.
  • Finite Element Analysis (FEA) – Structural, Thermal, and Fatigue Analysis for Mechanical Components.
  • Computational Fluid Dynamics (CFD) – Flow, Thermal Simulations, and High-Pressure System Analysis.
  • Kinematics & Dynamics – Static, Kinematic, and Dynamic Analysis, Mechanism Design, Vibration Analysis.
  • CAD/CAM Engineering Softwares – SolidWorks, Inventor, Fusion 360, SurfCAM, PowerMill, HyperMill.
  • Product Design & Development – Conceptualization, Prototyping, Testing, Mechanical System Optimization.
  • Pneumatic & Hydraulic Systems – Design, Control, Optimization, and High-Pressure Applications.
  • Manufacturing Processes – Machining, Casting, Forging, Welding, and Metal Fabrication.
  • Intellectual Property & Patents – Innovation Protection, Patent Filing, and Technology Commercialization.
  • Lean Manufacturing & Process Optimization – API, DS-1, ASME, ISO Compliance, Six Sigma, Continuous Improvement.
  • Project & Engineering Management – Multi-Project Leadership, R&D Strategy, Concept to Delivery Execution.
  • Quality Control & Reliability Engineering – Failure Analysis, Standards Compliance, Reliability-Centered Maintenance (RCM).

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Services:

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Our services include the study and design of customized projects involving the mechanical systems of computer numerical control (CNC) machines. This may entail designing water cutting systems (water jets), laser cutting and engraving systems, additive manufacturing, and 3D printing systems.
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We offer the study and design of custom projects related to the mechanical systems of industrial robots, which have either open-chain kinematics (series industrial robots) or closed-chain kinematics (parallel industrial robots).

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In addition to our custom project services, we provide mechanical design services to our clients and final-year engineering students, such as 3D mechanical modeling, product design, and drafting. Furthermore, we support engineering students with their graduation projects and scientific research.
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New!:
"TorboT" Mobile Robot:

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More Information
The "Torbot" mobile robot, with its simple four-wheeled design, has a wide range of potential applications. These may include use in dangerous environments, such as in space science or other hazardous fields. Additionally, it may be utilized for military purposes, such as for reconnaissance or other specialized operations. 

Projects:


Publications:
New!:
Robotics: Mechanics, Mathematical Analysis and Control

About The Book:
This book provides a mathematical introduction to the mechanics and control of robots that can be modeled as kinematic chains. Topics covered include the concept of a robot’s configuration space and degrees of freedom, static grasp analysis, the description of rigid body motions, kinematics of open and closed chain robots, dynamics of open chain robots, and the basics of robot control. The emphasis is not on the latest research trends and technological innovations in robotics, but on learning the fundamental concepts and core principles that underlie robotics as a scientific discipline. The intent is to help the reader acquire a unified set of analytic tools for the modeling and control of robots, together with a reliable physical intuition that recognizes the unique and interdisciplinary nature of robotics.

ISBN-13: 978-620-2-35681-7.
ISBN-10: 6202356812.
EAN: 9786202356817.
More Information
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Book Cover

Courses:
Ongoing Course:
Comprehension of Additive Manufacturing - Rapid Prototyping, Rapid Tooling, and Rapid Manufacturing:

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Go to Course
The course will include the following aspects:

1- Basics, definitions, and application levels.
2- Layer manufacturing processes.
3- Application of additive manufacturing.
4- Additive manufacturing strategies.
5- Materials, design, and quality aspects for additive manufacturing.

The course will consist of a large number of short-period videos. Although these videos will be short, they will be full of ideas and information, and will be supported by illustrative photos, tables, and figures to clarify the concepts properly.

Articles:
New!:
The Unspoken Challenge: Engineering in Uncertainty:

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Perfect data is a rarity, especially in the oil and gas sector, where engineers work under high-pressure timelines, volatile subsurface conditions, and constantly evolving field dynamics. Yet, design decisions must be made "responsibly".
This article explores a fundamental but often overlooked truth: "Engineering isn’t just about what’s known, it’s about how we design through what’s not".
It presents seven core practices that shift engineering from "assumption-blind" to "assumption-aware", and from idealized design to resilient performance under uncertainty.
Whether you're an engineer, manager, or technical leader, this mindset is no longer optional, "it’s essential".

Read Article

Documents:

Documents

Lectures:
​New!
Machine Design – Topology Optimization: practical example using “Shape Generator” new tool in Autodesk Inventor Professional 2017:


In this practical lecture, I will provide you with a detailed explanation of how to apply the concept of topology optimization using the "Shape Generator" tool, a new feature added by Autodesk company to its package of Inventor Professional 2017 for 3D engineering design.
Watch Lecture
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Contributions: 

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The Muslim Researchers
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The Syrian Engineers
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Arab Robotic Association

The Library:
New!

Library

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    For any inquiries or assistance, please contact me.

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Eng. Rami Khalil

Services

  • CNC Machine Design
  • Robotic System Design
  • Mechanical Design Services

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