Mechanical Characterization and Standards Development for Material Testing, Developed and standardized mechanical testing protocols for tensile, compression, peel, shear, bending, and fracture tests to perform material analysis and property validation. Enhanced scope of testing for diverse materials, utilizing Digital Image Correlation (DIC) and finite element analysis (FEA) to improve the mechanical performance of tested materials. Process Control and Manufacturing Improvement of Advanced Polymeric Material, Integrated optimized process control and manufacturing techniques with novel approaches such as SEM, Optical Microscopy, and ANSYS for material characterization, and energy absorption. Expanded the scope to conduct full-field analyses of density-graded polymers, employing Digital Image Correlation (DIC) for accurate measurements with a notable 106% improvement in load-bearing capacity. Innovative Additive Manufacturing Techniques for Polymer Fabrication, Optimized fused deposition modeling (FDM) parameters to enhance the fabrication of polymer structures, with thermal imaging and mechanical testing to achieve superior layer adhesion and structural integrity. Developed precise stereolithography (SLA) curing and resin protocols, leveraging photopolymer dynamics analysis to produce high-definition polymer parts with increased durability and finer surface finishes. Redesigning Packaging Dynamics: Engineered and Bioinspired Metamaterial for Superior Safety, Conducted in-depth analysis of honeycomb packaging designs, utilizing SEM and optical microscopy, digital Image Correlation (DIC) and ANSYS for comprehensive strain field characterization. Achieved a remarkable 78% increase in crashworthiness, applicable to reliable packaging enhancements. Cold Spray Additive Manufacturing Coating for Composite Repair, Optimized process parameters and bonding mechanisms in cold spraying of polymers on metal, composites. Implemented polymeric coating with cold spray additive manufacturing to repair damaged fiber-reinforced polymer composites up to 118% for enhanced durability and functionality. Enhancement of Composite Structure Conductivity in Next-Gen Aircraft, Automobile, Energy Sectors, Developed and optimized cold spray process parameters for the application of polymeric conductive coatings on composites, for enhanced adhesion strength and extended lifecycle. Conducted mechanical testing and evaluation to assess improvements in material performance, targeting applications in aerospace, automobile, and marine structures.