I am James Carchrie, a senior mechanical engineer with over 10 years of hardware product development and analysis, focused on light electric vehicles. I enjoy turning complex ideas into robust, manufacturable solutions through careful design, rigorous testing, and hands-on prototyping. I thrive on de-risking projects through engineering rigor, DFMEA, FEA correlation with physical testing, and close collaboration with manufacturers to optimize cost, lead times, and serviceability for long-term value.…

James Carchrie

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I am James Carchrie, a senior mechanical engineer with over 10 years of hardware product development and analysis, focused on light electric vehicles. I enjoy turning complex ideas into robust, manufacturable solutions through careful design, rigorous testing, and hands-on prototyping. I thrive on de-risking projects through engineering rigor, DFMEA, FEA correlation with physical testing, and close collaboration with manufacturers to optimize cost, lead times, and serviceability for long-term value.…

Available to hire

I am James Carchrie, a senior mechanical engineer with over 10 years of hardware product development and analysis, focused on light electric vehicles. I enjoy turning complex ideas into robust, manufacturable solutions through careful design, rigorous testing, and hands-on prototyping.

I thrive on de-risking projects through engineering rigor, DFMEA, FEA correlation with physical testing, and close collaboration with manufacturers to optimize cost, lead times, and serviceability for long-term value.

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Language

English
Fluent

Work Experience

Freelance Mechanical Engineer at Carchrie Engineering
June 1, 2017 - Present
Consultancy offering end-to-end services covering concept development, CAD, prototyping, testing, and preparation for mass manufacture. Produced detailed CAD models and assemblies using Fusion 360 and SolidWorks, including parametric and generative designs. Conducted FEA simulations and correlated with physical testing to optimise designs for ISO safety standards and mechanical performance. Developed saddle and frame designs for cycling industry clients. Created rapid prototypes, test rigs, and fixtures to validate function and streamline development. Managed project risk and liaised with manufacturers locally and overseas to refine designs, support tooling, pilot production, and scale-up.
Senior Mechanical Design Engineer at Zoomo
September 1, 2021 - Present
Lead Mechanical Engineer for a global light electric vehicle manufacturer and service provider. Utilised CAD and FEA to develop next generation of e-bikes and accessories. Applied DFMEA to ensure safety and reliability, with designs optimised for injection moulding, sheet metal, extrusion, and CNC manufacturing. Focused on heavy-use scenarios, designing for serviceability and reduced total cost of ownership. Performed forensic engineering to pinpoint failures and implement re-designs. Liaised with customers and stakeholders to present root cause analyses and containment actions. Developed new test standards for high-use scenarios and component lifetime assessment.
Modelling and Simulation Analyst at Thornton Tomasetti
January 1, 2020 - September 1, 2021
Performed dynamic and shock analysis on naval and civilian structures, delivering bespoke analytical solutions. Led training for proprietary FE simulation tools and managed knowledge transfer. Produced client-facing technical reports and numerical analyses, applying non-linear methods for explosive decommissioning scenarios. Supported trials teams with onsite data capture and safety/compliance.
Research and Design Engineer at Frog Bikes
May 1, 2018 - May 1, 2019
Led component design for a global bicycle manufacturer. Applied engineering research to manage technical risk and reported progress to investors and senior leadership. Delivered manufacturable frame designs using CAD and FEA, and built a simple data-capture system to assess component performance.

Education

MEng Mechanical Engineering (2:1) at Heriot-Watt University, Edinburgh
January 1, 2013 - January 1, 2018

Qualifications

NAFEMS Training - Fatigue and Fracture Mechanics in FEA
January 11, 2030 - January 6, 2026
Full AUS Driving Licence
January 11, 2030 - January 6, 2026
Velotech Gold Award – Professional bicycle mechanic qualification
January 11, 2030 - January 6, 2026

Industry Experience

Manufacturing, Transportation & Logistics, Professional Services
    uniE621 Protective Silicone Cover Development
    Due to water ingress issues a waterproof silicone case was developed for electric bikes to mitigate against damage to electronics. An initial prototype sample was 3D printed in material representative of silicone to validate the design prior to mass production. This allowed for functional testing and further adjustments to the CAD model prior to investing in production tooling. Comprehensive engineering documentation, including manufacturing and assembly drawings was then used to mass produce the protective covers.…
    uniE621 Light Electric Vehicle Development
    The Zoomo One was designed from scratch as a best-in-class electric delivery vehicle to rival petrol mopeds, specifically for last-mile delivery and quick commerce. Carchrie Engineering led the mechanical design, development, analysis and manufacture of the full vehicle. Successful delivery of the award-winning Zoomo One was achieved through close collaboration with industrial designers, electrical engineers, and key stakeholders. Comprehensive engineering documentation, including manufacturing and assembly drawings and structural analysis reports, validated the design's feasibility. mechanicalengineering manufacture industrialdesign engineering…