Design and Mechanical Engineer based in London (Islington, Hackney and Camden), experienced in developing medical devices, consumer, and industrial products. Always looking for elegant and efficient solutions that deliver an exceptional user experience. Experienced in detailed and complex CAD modelling, mechanism design, material selection, FEA, design for manufacturing, prototyping and testing.
Within engineering, there are several areas where I have experience. Here is a short description of some of them.
I see this area as the meeting point of all the disciplines involved in product development. This is where it is critical to understand the balance between all elements and requirements of the product and find the best embodiment that will deliver the ideal outcome.
Most of the work centres around a CAD package. I use primarily SolidWorks and Fusion 360, but also have experience with other packages such as Creo and Inventor. Good use of CAD is vital to create models efficiently that are robust, easy to handle, fast to share and adaptable.
Systems engineering requires a good understanding of all stakeholders, project objectives, regulations, product requirements and technical challenges. Most of my work centres on this field, managing multidisciplinary teams to develop products with complex systems.
A critical aspect of systems engineering is knowing how to prioritize tasks, give clear instructions to the team, and ensure deliverables are adequate for the product. Different tools can be used in this area, but common sense, experience, leadership and sound technical knowledge remain the best options.
This field covers all the details required to deliver the functional aspects of a product. It spans a great deal of sub-disciplines required across all product developments, especially in complex systems.
My approach to engineering is to first understand the challenge from a first-principles perspective, then find innovative solutions to complex problems using a combination of analytical, heuristic and iterative processes. In this area I combine calculations and simulations using software such as FEA and CFD, always followed by prototyping and testing.
Computer simulation is a common tool in product development that should be used whenever possible. There are several areas where simulation is particularly useful: stress analysis, thermal analysis and fluids.
In stress analysis, we look to find the geometry that uses the least material possible while remaining manufacturable and mechanically sound. Aspects we examine include impact tests, drop tests, and deformation under given forces and pressures. The tool we use is Finite Element Analysis, where a CAD model is analysed and optimized under a range of conditions, then evaluated and tested on prototypes to corroborate accuracy.
Another area is thermal and fluid analysis, usually covered by multiphysics simulation programs or CFD (Computational Fluid Dynamics). Here we simulate thermal performance or how fluids behave within the product — useful for everything from a hairdryer to an asthma inhaler.
My experience with these tools lets me know when it's best to use them and how to use them efficiently to find answers and solutions in a fast, cost-effective process.
I work either as contractor, consultant, or independent freelancer, supporting start-ups, entrepreneurs, consultancies and manufacturing companies in the development of innovative products and breakthrough technologies. I am based in Cambridge and London (Islington, Hackney and Camden).
Find out more on how I work, or get in touch.
Tell us about the project — what stage it's at, and what you need help with.
Or email directly:
xorge@x-castro.com