Led the product design of CNC Concrete 3D Printers using Solidworks. Designed and developed mechanical systems and components for CNC concrete 3D printers from concept to production. Performed DFMEA to identify design risks, created detailed manufacturing drawings using GD&T, and conducted FEA and simulations to validate designs ensuring structural integrity and reliability. Tested and validated prototypes and production machines, collaborated with cross-functional teams, applied DFM and DFA principles for cost-effective production, managed materials selection and sourcing, and prepared BOMs and manufacturing documentation.

Freelance Mechanical Design Engineer at SMEKO LLC – Remote, USA

January 1, 2025 - July 25, 2025

Led product design of a new concept Roller Ball Pen and its Refill Unit using Solidworks. Responsibilities included knowledge extraction through patent reviews, proof of concept design, concept visualization, mechanical parts sourcing, detailed design and BOM generation, DFMEA preparation, design validation using FEA, prototyping using high precision 3D printing and CNC machining, as well as applying DFM and DFA principles.

Mechanical Design Engineer, Founder at Egyptian Workshop – Gharbia, Egypt

February 1, 2022 - July 25, 2025

Led product design of CO2 Laser Cutters using Solidworks with FEA design validation, responsible for sourcing, manufacturing, and testing. Designed various types and sizes of CO2 laser cutters with different machine structure approaches. Applied 5S principles to workshop organization. Improved DFM/A by reducing components and assembly operations, optimized BOMs and drawings, used poka-yoke principles for assembly facilitation, introduced 3D printing to reduce machining costs, performed CFD and dynamic analysis, collaborated with software teams, designed using Solidworks weldments and GD&T, optimized sheet metal design, created CNC machining toolpaths, learned welding techniques, and carried out system assembly, calibration, and testing.

Research & Development Engineer in DLP 3D Printing at 3D Scales – Beirut, Lebanon

October 1, 2017 - July 25, 2025

Invented a new system for continuous DLP 3D printing using liquid matrix support (patent #10232552). Designed 3D mockups using Solidworks, supported chemical team on resin formula development, performed DOE to optimize research process, performed root cause analysis of early failures, collaborated on software development to improve 3D printing reliability and performance, prepared 3D models for printing, sourced manufacturers for prototype parts and used different in-house 3D Systems printers.

Senior Mechanical Design Engineer at LAYN – Cairo, Egypt

March 1, 2025 - Present

Led the product design of CNC Concrete 3D Printers using Solidworks, designing and developing mechanical systems and components from concept to production. Performed DFMEA to identify and mitigate design risks, created detailed manufacturing drawings with GD&T, and conducted FEA and simulation methods to validate designs. Led testing and validation of prototypes, collaborated with multidisciplinary teams, applied DFM and DFA principles, managed materials selection and mechanical parts sourcing, and generated technical documentation and BOMs.

Freelance Mechanical Design Engineer at SMEKO LLC – Remote, USA

January 31, 2025 - July 25, 2025

Led the product design of a new concept Roller Ball Pen and its refill unit using Solidworks. Responsibilities included patent review and knowledge extraction, proof of concept design, concept visualization, parts sourcing, detailed design and BOM generation, DFMEA preparation, mechanical parts selection based on calculations, design validation via FEA, prototyping using various 3D printing technologies and CNC machining, and applying DFM and DFA principles.

Mechanical Design Engineer, Founder at Egyptian Workshop – Gharbia, Egypt

February 28, 2022 - July 25, 2025

Led product design of CO2 Laser Cutters using Solidworks, applied FEA for design validation, and managed sourcing, manufacturing, and testing. Designed various types and sizes of laser cutters with different machine structures. Organized the workshop using 5S principles, improved DFM/A on subassemblies by reducing components and assembly operations, used Poka-Yoke principles to facilitate assembly, introduced 3D printing to reduce machining costs, performed linear dynamic and CFD analyses, collaborated with software teams developing laser cutting software, and used Solidworks for weldments, drawings, GD&T, and CNC toolpaths. Also skilled in TIG and MIG welding and mechanical system assembly, calibration, and testing.

Research & Development Engineer in DLP 3D Printing at 3D Scales – Beirut, Lebanon

October 31, 2017 - July 25, 2025

Invented a new system for continuous DLP 3D printing using liquid matrix support (Patent number: 10232552). Designed 3D machines' mockups using Solidworks and supported chemical department on resin development. Performed DOE to optimize research, root cause analysis for early failures, collaborated on software development for 3D printing reliability and performance, prepared models for printing using Materialise Magics software, sourced prototype parts, and had hands-on experience with various in-house 3D Systems printers.

Education

Bachelor of Engineering at Faculty of Engineering – Tanta University

January 1, 2010 - June 1, 2013

Bachelor of Engineering at Faculty of Engineering – Tanta University – Tanta, Egypt

January 1, 2009 - June 30, 2013

Qualifications

Certified Solidworks Expert – CSWE Mechanical Design

January 1, 2015 - December 31, 2015

Certified Solidworks Professional – CSWP Mechanical Design

January 1, 2015 - December 31, 2015

Certified Solidworks Professional – CSWP Advanced Surfacing

January 1, 2015 - December 31, 2015

Certified Solidworks Professional – CSWP Advanced Weldments

January 1, 2015 - December 31, 2015

Certified Solidworks Professional – CSWP Advanced Mold Tools

January 1, 2015 - December 31, 2015

Certified Solidworks Professional – CSWP Advanced Sheet Metal

January 1, 2015 - December 31, 2015

Certified Solidworks Expert – CSWE Mechanical Design