I am a Senior Mechanical Design & Additive Manufacturing Engineer with a passion for innovation and efficiency. My career has revolved around the design and optimization of mechanical systems, where I bring deep expertise in 3D printing and prototyping. I thrive on tackling complex challenges, pushing the boundaries of technology to create cutting-edge solutions in the engineering field.…

Muhammad Raheel Rafeeq

I am a Senior Mechanical Design & Additive Manufacturing Engineer with a passion for innovation and efficiency. My career has revolved around the design and optimization of mechanical systems, where I bring deep expertise in 3D printing and prototyping. I thrive on tackling complex challenges, pushing the boundaries of technology to create cutting-edge solutions in the engineering field.…

Available to hire

I am a Senior Mechanical Design & Additive Manufacturing Engineer with a passion for innovation and efficiency. My career has revolved around the design and optimization of mechanical systems, where I bring deep expertise in 3D printing and prototyping. I thrive on tackling complex challenges, pushing the boundaries of technology to create cutting-edge solutions in the engineering field.

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Language

English
Advanced

Work Experience

Senior Mechanical Engineer at Mindtune Innovations
March 1, 2025 - Present
Architected the mechanical design of EEG earbuds, enabling integration of a PCB footprint 300% larger than standard commercial earbuds. Iterated through three design generations, achieving a ~20% reduction in overall form factor with each version while preserving structural integrity and ergonomics. Optimized PCB boundary geometry to maximize volumetric efficiency inside ultra-compact cavities of both the earbuds body and their case. Diagnosed and corrected charging circuit inconsistencies, reaching ~92% charging reliability in the third hardware revision.
Senior Mechanical Engineer at Panhwar Jet LLC
July 1, 2023 - January 1, 2025
Led 3D printing initiatives for prototype aircraft components, improving part accuracy by 15% and reducing print time by 20%. Developed optimized CAD-to-print workflows and validated printed components through FEA and tolerance testing. Managed prototyping cycles using FDM and SLA printers for molds and fixtures, achieving a 10% rework ratio. Collaborated with suppliers to evaluate print materials and ensure consistency in surface finish and mechanical strength.
Assistant Manager – Mechanical Design at AERO
January 1, 2020 - June 1, 2023
Established an internal thermal testing lab, enabling in-house rapid prototyping and concept validation. Integrated 3D printed polymer prototypes into mechanical assemblies, reducing product development lead time by 25%. Conducted FEA analysis to validate 3D printed parts and ensured dimensional accuracy through post-processing techniques. Trained design teams in CAD-to-print preparation.
Design Engineer at Genesis Solutions
May 1, 2017 - December 1, 2019
Designed mechanical components for industrial systems. Simplified surface treatment process with R&D in anodizing. Coordinated with fabrication partners for transitioning from prototype to production tooling.

Education

M.E. at NED UET
January 1, 2020 - January 1, 2022
B.E. at NED UET
January 1, 2012 - January 1, 2016

Qualifications

Advanced FEA & Fatigue Analysis – ANSYS / Abaqus
January 11, 2030 - April 8, 2026

Industry Experience

Manufacturing
    paper UAV Fixed Wing: Control System Design of Flight Control Surfaces

    Actuator selection for a UAV was carried out as per aerodynamic loads. Validation with simulations, both in Solidworks (kinematic) and ANSYS (dynamic) models

    paper Branded AI content for smart wearable

    With the help of AI tools, EEG earbuds and glasses photo-shoots and reels are generated. Since earbuds and glasses are custom made, hence specialized coordination between CAD and AI image generation is built for continuous theme photo-shoots. Both earbuds and glasses are snapped in marketing environments of stores as well as models wearing the products

    paper AI Speaker Housing

    This project is related to enclosure design for an AI based speaker ( similar to Amazon Alexa). The key requirement of this design is to achieve similar sound quality as like Amazon Alexa but in a 3D printed box. Box is defined with additive manufacturing approach in Ansys. FDM printed properties( ABS) are used to develop FEA model and further sound analysis has shown the required wall thickness for optimum speaker performance