About Me
Hi there!
I'm Ilhan Esmail, an engineer and tech enthusiast based in Montreal, Canada. I've always been fascinated by bridging the gap between innovation and practicality - whether its training AI models to mimic structural properties of bio-inspired materials or prototyping and sending 3D printed parts to the International Space Station. Here's what I've been up to:
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I lead a talented team of engineers as the Applications Engineering manager of a Y-Combinator backed tech start-up in 3D printing.
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Recently, I've been building the UI/UX of a next generation 3D printer while automating the workflow so anyone could use the technology.
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Before 3D printing, I spent 2 years on materials research and published 3 papers on bio-inspired architectured ceramics design for impact shielding.
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I run an annual workshop on Deep Learning and Neural Network design using Python at McGill University.
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Feel free to reach out - whether it's about 3D printing, materials science, or to discuss any of my projects!
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PROFESSIONAL HISTORY
APPLICATIONS ENGINEERING MANAGER - AON3D
September 2021 - Present
At AON3D, I lead an incredible engineering team, working on cutting-edge projects that push the boundaries of 3D printing. One of the highlights? Helping send 3D-printed parts to the International Space Station in collaboration with NASA and the CSA.
I’ve focused on making 3D printing more accessible and efficient by enhancing user experiences—like refreshing our product’s interface in Fluidd using Figma and automating workflows with Klipper and Python. I also drive innovation in hardware and software, using data from sensors and thermal simulations to tackle projects that were once out of reach for the technology.
Efficiency is a big deal for me. By streamlining workflows and automating tasks with Agile in Jira, I cut project lead times from 30 days to just 14, all while improving the quality of our print farm’s output.
CO-OP STUDENT RESEARCHER - NATIONAL RESEARCH COUNCIL OF CANADA
September 2019 - June 2021
​As a student researcher, I worked on some exciting projects that combined engineering and AI. Using Python, OpenCV, and TensorFlow, I developed a Convolutional Neural Network to classify natural biological structures, which helped researchers create ceramics that were 220% tougher than their monolithic counterparts.
​I took the lead on four research projects, drafting manuscripts, creating detailed reports and visualizations for government grants, and collaborating with prominent materials engineers in the field. Along the way, I also published a peer-reviewed journal article as one of the youngest first authors at the NRC, focused on bio-inspired ceramics manufacturing.
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To make life easier for researchers, I automated tensile and quasi-static testing processes with Python, cutting analysis time by 70%. I even dived into FEA simulations, validating how carbon nanotube composites handle heat deformation for smart robotics in collaboration with the University of Toronto.
PRESIDENT OF THE McGill Institute for Aerospace Engineering (SEC)
May 2019 - May 2021
​As president of McGill’s student-run aerospace institute, I focused on bridging the gap between students and the aerospace industry. By turning industry hiring needs into practical workshops, I helped over 300 students boost their technical skills and career readiness.​​​
Leading the committee was all about teamwork—I coordinated tasks within the organization, analyzed attendance data for insights on event planning, and organized virtual events (during COVID) that connected students, professors, and industry pros - a time when networking and finding a job after graduating was extremely challenging.
CALCULUS 3 TEACHING ASSISTANT - MCGILL UNIVERSITY
September 2020 - December 2020
As a Calculus 3 TA at McGill, I managed a class of 130 students, designing tutorials that addressed their needs by analyzing weekly polling data. I spent two hours prepping each week to make sure my sessions were engaging and helpful.
During the virtual semester in 2020, I got creative with communication, using Discord and Zoom to connect with students more effectively. This approach sped up response times for questions and fostered better collaboration among classmates.
UNDERGRADUATE RESEARCH ASSISTANT - ADDITIVE MANUFACTURING LAB
May 2019 - August 2019
As an undergraduate research assistant, I explored how chemistry and crystallographic orientation affect stress in 3D-printed stainless steel using X-ray diffraction analysis. This helped me understand how residual stresses form and distribute in these components.
I also worked on optimizing printing paths by testing different raster geometries, ultimately helping create stainless steel blocks with significantly lower residual stress.
Some wholesome feedback from my time as a tutor
There is more structure and organization to this tutorial than most of my classes.
MATH 262 - Intermediate Calculus for Engineers (Calculus 3)
Niloy Barua
Ilhan was very prepared and patient with me! He helped me a lot and made sense of a low of essentials that I didn't understand. Thank you so much!
CHEM 110 - General Chemistry
Rating: 5.0/5.0
Iskra Alikalfic
Structured material and efficient problem solving. Ilhan knows how to explain hard and complex concepts through basic examples.
MIME 356 - Fluid Dynamics + Heat and Mass Transfer
Rating: 5.0/5.0
Ralph Khayat
He was so prepared for the [tutorial] session and it was super helpful!
COMP 208 - Computers in Engineering (C, MATLAB)
Rating: 5.0/5.0
Kevin Hou
Helpful in explaining different concepts and any questions we had. Was prepared with different problems to do!
MIME 262 - Intermediate Calculus (Calculus 3)
Rating: 5.0/5.0