Ken Mao

Professor Ken Mao is a Mechanical Engineering academic at the University of Warwick's School of Engineering. He specializes in polymer composite materials, gear design optimization, and tribology applications across automotive, healthcare, and additive manufacturing domains. His research integrates advanced numerical simulations with experimental validation methods.

Research focuses include:

• Lightweight polymer composite gear systems for EVs and motorcycles
• Non-linear FEM analysis of gear transmission and tyre contact systems
• 3D printed polymer gear performance under dynamic loads

Over 100 peer-reviewed publications demonstrate his work on polymer gear wear mechanics, additive manufacturing parameters, and biocompatible materials. Active industrial collaborations include projects with TVS Motors, Innovate UK, and DSM.

Teaching responsibilities include advanced mechanical design modules covering finite element methodologies and lightweight gearbox optimization principles.

Current projects:

• Lightweight motorcycle gearbox development (funded by TVS Motors)
• Innovate UK-supported polymer gear design initiatives

Office location: F327 School of Engineering, Coventry CV4 7AL. Advice hours: Wednesdays 11:00-13:00 during term time.