Available to hire
With nearly a decade in various tech and design industries, I specialize in full product development, rapid prototyping, DFMEA/DFM and reverse engineering. My Solidworks CAD skills enable me to tackle complex surfacing, large assemblies and 3D scan data to create accurate, manufacturable models and precise technical drawings.
I also maintain a fully equipped prototyping workshop with multiple FDM and SLA printers and a range of prototyping equipment to turn concepts into tangible products quickly.
Experience Level
Expert
Expert
Expert
Expert
Expert
Intermediate
Intermediate
Intermediate
Language
English
Fluent
Work Experience
Founder at the design lab ltd.
June 1, 2023 - PresentFounder and lead designer running a prototyping and design consultancy; responsible for end-to-end product development, rapid prototyping, DFM, and reverse engineering for diverse clients; established workshop with multiple 3D printers and prototyping equipment.
Contract Mechanical Design Engineer at Percival Aviation Ltd.
February 1, 2005 - July 1, 20053D scan and reverse-engineering of aircraft interiors focusing on legacy parts with limited documentation; converted scan data into accurate meshes and CAD models using Geomagic and SolidWorks; produced manufacturing drawings to aerospace tolerances and supported reviews; collaborated with in-house teams to verify fit, materials, and installation; balanced on-site and remote work for fast turnaround on concurrent briefs.
Concept Designer at Interpreter Earpiece - Confidential Client
April 1, 2025 - July 1, 2025Led concept and form development for an AI-powered interpreter earpiece, benchmarked commercial products, produced SLA and FDM prototypes, refined CAD with physical testing, and adjusted boom position, battery angle, and ear arm design.
Lead Product Designer at Confidential Client
January 1, 2025 - PresentLeading ergonomic form development and mechanical feasibility studies for a compact wearable medical device; prioritised user comfort, skin contact, and miniaturisation; created and tested mock-ups via FDM and SLA.
Product Designer at Confidential Client (Lower-Back Wearable)
November 1, 2024 - February 1, 2025Developed ergonomic form, internal layout, and mechanical feasibility for a wearable; tested multiple mock-ups for form, feedback feel, and enclosure strategy.
Contract Product Designer at Paradigm Evergreen Inc. (Eeva)
October 1, 2023 - February 1, 2024End-to-end product design for home appliances; developed portable washing machine and tumble-drying technology; prototyped concepts and scaled up prototyping/testing capabilities; implemented development processes to speed up iterations; prepared designs for China handover.
Contract Product Designer at Shark Ninja
June 1, 2023 - October 1, 2023Developed 2025 Advanced Development personal care concepts; performed rapid iterative CAD surface modeling and prototyped multiple concepts; researched markets/trends and supported NPD.
Product Designer at Emteq Labs
April 1, 2022 - April 1, 2023Led physical product design for wearable tech; developed VR headset and AR glasses from idea to production; mapped sensor positions and ergonomics; created test rigs to assess sensor performance; collaborated across marketing, electronics, firmware and data science; used DFM to ensure manufacturability.
Mechanical Design Engineer at Hosiden Besson Ltd.
January 1, 2019 - April 1, 2022Led design of electronic acoustic devices for fire safety, automotive and hearing protection; reduced cost by simplifying designs and tooling; built complex SolidWorks models; supported rapid prototyping; introduced silicone prototyping and seals; liaised with multiple departments to reduce product assembly time.
Mechanical Design Engineer at Kent Periscopes Ltd.
March 1, 2018 - September 1, 2018Developed optical products for defence clients with high-detail requirements; implemented new 3D printing solutions for jigs to reduce costs; reverse-engineered legacy hand-drawn drawings; used SolidWorks for complex opto-mechanical assemblies; followed BS8888 drawing standards.
Product Designer at Design Reality Ltd.
February 1, 2015 - March 1, 2018Secured full-time position in PPE design consultancy; developed in-house test methods aligned to ISO standards; progressed to senior responsibilities including DFM and project planning; managed workshop and 3D printing/silicone moulding capabilities; collaborated with clients to update progress and advising suggestions.
Lead Product Designer at Confidential Client - Medical Wearable
January 1, 2025 - PresentLed the development of ergonomic form, internal layout, and mechanical feasibility studies for a compact wearable medical device for rehab using heat and haptic feedback. Prioritised user comfort, skin contact, and part miniaturisation for discreet daily use. Created and tested functional mock-ups via FDM and SLA to evaluate form, feedback feel, and enclosure strategy.
Contract Mechanical Design Engineer at Percival Aviation Ltd
February 1, 2025 - July 1, 2025Performed 3D scan and reverse-engineering of aircraft interiors focused on legacy parts with limited documentation. Converted scan data into accurate meshes and CAD models using Geomagic and SolidWorks. Supported design updates and part replacements for airline refurb projects, produced manufacturing drawings to aerospace tolerances, and collaborated with internal teams to verify fit and installation requirements.
Concept Designer at Confidential Client
April 1, 2025 - July 1, 2025Led concept and form development for an AI-powered interpreter earpiece, with a focus on long-term wearability and user comfort. Benchmarked over a dozen commercial products, conducted teardowns to assess internal layout and ergonomics, produced multiple prototypes, and refined CAD in parallel with physical testing.
Product Designer at Confidential Client
November 1, 2024 - February 1, 2025Designing a compact wearable medical device for targeted rehabilitation using heat and haptic feedback; led ergonomic form, internal layout, and mechanical feasibility studies; prioritised comfort, skin contact, and miniaturisation; created and tested functional mock-ups via FDM and SLA.
Contract Design Manager at Interior Lighting, Trade Ivy Ltd (SOHO Lighting, Enkin & Lieber)
March 1, 2024 - July 1, 2024Evolved from freelance to contract design management; reverse engineered solar technology projects for efficient off-grid outdoor lighting; implemented full end-to-end product design from brief to manufacture; developed solar systems, solar panels, voltage converters, PCBs and battery arrays in Solidworks; created project roadmaps and handovers for development in China; trained technical team on efficient product development practices; hand-made large prototypes for Chelsea Flower Show 2024.
Mechanical Design Engineer at Hosiden Besson Ltd
January 1, 2019 - April 1, 2022Led design of electronic acoustic devices for fire safety, automotive and hearing protection; reduced costs by simplifying designs and using common parts; created complex Solidworks CAD models and assemblies; leveraged 3D printing to cut prototyping time by over 50%; developed silicone seals for testing; cross-department collaboration to reduce assembly time.
Mechanical Design Engineer at Kent Periscopes Ltd
March 1, 2018 - September 1, 2018Developed optical products for defence clients; introduced new 3D printing solutions for jigs reducing jig costs by 80%; reverse engineered legacy hand-drawn drawings to digital CAD; created robust opto-mechanical assemblies using Solidworks; used Javelin PDM for workflow and revisions; followed BS8888 drawing standards.
Product Designer, Consultancy at Design Reality Ltd.
February 1, 2015 - March 1, 2018Secured full-time position after a short-term work placement; established in-house test methods aligned with Iso standards to improve testing reliability; regularly assumed senior responsibilities (DFM and planning); developed CAD skills in Creo for PPE respiratory products; collaborated closely with clients to update progress and advise on development.
Education
BSc. Product Design (2:1) at Bangor University
January 1, 2014 - January 1, 2017A-Levels (Product Design, Maths, Physics) at Eirias High School
January 1, 2011 - January 1, 2014GCSEs at Eirias High School
January 1, 2006 - January 1, 2011Qualifications
Industry Experience
Manufacturing, Healthcare, Life Sciences, Media & Entertainment, Consumer Goods, Professional Services, Software & Internet, Education
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