Ph.D., Physics (Optics | Computational Modeling | Nano fabrication)
Aug 2016 to Oct 2021 | University of California, Merced.
M.S., Physics
2016 | Binghamton University (SUNY) , Binghamton, NY.
Metrological Process Engineer (CD-SEM) at Intel Corporation
Intel Corporation, Hillsboro, USA. | Nov, 2021 - August, 2025
- Optimized fleet-wide measurement stability for 8 high-precision CD-SEM systems in a 24/7 high-volume manufacturing environment. Leveraged Statistical Process Control (SPC) and automated calibration logic to minimize measurement drift and maximize yield.
- Engineered an automated anomaly detection system using Python to monitor high-dimensional sensor data (beam parameters, stigmation). Transitioned the team from reactive troubleshooting to proactive system optimization through real-time data visualization.
- Automated multi-variate statistical pipelines to evaluate tool-to-tool matching and measurement precision for DCCD process. Reduced data processing time by 75%(from ~5 hrs to less than 1 hour) while improving reporting accuracy for fleet-wide consistency checks. Developed Python workflows for processing FCCD datasets and integrating results into long-term SPC systems.
- Built a Python/OpenCV toolkit for automated SEM image quality assessment (sharpness, CNR, FFT-sharpness, GLCM texture metrics).
- Collaborated with cross-functional team for SEM metrology stability, coordinating with hardware and software integration teams to troubleshoot complex electron-optical drift and optimize image acquisition.
Graduate Research Scholar
University of California, Merced, California. | Aug, 2016 - Oct, 2021
- Computational Modeling & Nano-fabrication of Plasmonic Metastructures:
- Developed a hybrid full-wave modeling framework combining the Method of Fundamental Solutions (MFS) and Foldy–Lax multiple-scattering theory to simulate scattering from dielectric cores coated with plasmonic nanoparticle assemblies.
- Implemented Python and MATLAB solvers to compute far-field angular scattering, extinction and scattering spectra, anisotropy, and albedo across large design parameter spaces.
- Performed systematic parameter sweeps (particle size, filling fraction, core geometry) to identify regimes of scattering suppression, angular redistribution, and broadband cloaking.
- Nano-fabricated core–shell plasmonic structures, characterized geometry using SEM, and correlated experimental scattering measurements with simulation predictions.
- Demonstrated strong agreement between modeled and measured optical response, validating the computational framework and enabling predictive metastructure design.
- Designing and aligning a high-stability TRPL measurement system optimized for dilute samples and weak emitters
- Preparing and characterizing DNA-origami scaffolds with nanometer-precise AuNC/fluorophore placement (5–17 nm separation) to test distance-dependence limits of energy transfer models.
- Measuring and analyzing photoluminescence intensity quenching and lifetime changes to identify whether energy transfer in AuNC systems follows Förster-type (FRET) or nanoparticle-based NSET models
- Mentoring undergraduate researchers, co-developing experimental protocols, and contributing data to multiple CCBM projects. Collective Motion with Kilobot Swarms (UC Merced, 2016-2017)
During my PhD, I developed physics-based computational models to study light–matter interactions in three-dimensional plasmonic metastructures, combining rigorous electromagnetic theory with scalable numerical implementations. This work focused on understanding how collective scattering, absorption, and disorder in nano-assembled systems can be engineered to control far-field optical response.
Key contributions included:My research works resulted in peer-reviewed publications in JOSA A and Optics Express and laid the foundation for my current interest in surrogate modeling, physics-informed learning, and data-driven approaches for complex imaging and wave-based systems.
Optical Metrology for Nanoscale Energy Transfer(UC Merced, 2017-2019)I conducted optical metrology experiments to probe non-radiative energy transfer in DNA-templated gold nanoclusters (AuNCs) and fluorophores. Using time-resolved photoluminescence (TRPL) and custom-built optical setups, I quantified changes in emission lifetime and intensity to distinguish FRET-like versus NSET-like transfer mechanisms in atomically precise gold nanoclusters.
Worked with large-scale Kilobot swarms (~110 units) to study collective motion and active-matter dynamics, integrating simulation models with hardware experiments using IR-based control. Contributed to system revival, firmware debugging, experimental design, and presented results at APS regional and national meetings.
Graduate Research Associate
Universal Instruments Corporation, Conklin, New York. | 2013-2014
- Characterized thermomechanical properties of lead-tin-silver alloys for high-temperature electronic packaging.
- Conducted DSC analysis to determine melting point depression and thermodynamic behavior.
- Performed SEM-based microstructural analysis to link material composition with grain morphology.
- Measured mechanical integrity using a Dage 4000 Plus bond tester and co-authored an IMAPS industry publication.
- Co-authored an industry-facing publication for the International Microelectronics Assembly and Packaging Society (IMAPS), presenting findings to aid in the development of new industrial alloys.
- Khan, M.I., et al., “Scattering by nanoplasmonic mesoscale assemblies,” JOSA A 42, 1244–1253 (2025).
- Khan, M.I., et al., “Modeling broadband cloaking using 3D nano-assembled plasmonic meta-structures”, Optics Express, 2020.