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I am a senior mechanical engineer and independent product developer with 25+ years of hands-on 3D modeling, prototyping, and design-for-manufacture work. I specialize in SolidWorks and Fusion 360, delivering production-ready STL files and complete drawing packages for consumer products, industrial hardware, and medical devices. I work remotely on project-based engagements, translating complex requirements into manufacturable geometry, advising on tolerances, material choices, and production readiness across FDM, SLA, DLS, and metal sintering. I also lead DFMA analyses, design-to-cost studies, and cross-functional collaboration to move concepts from idea to validated production releases.…I am a senior mechanical engineer and independent product developer with 25+ years of hands-on 3D modeling, prototyping, and design-for-manufacture work. I specialize in SolidWorks and Fusion 360, delivering production-ready STL files and complete drawing packages for consumer products, industrial hardware, and medical devices. I work remotely on project-based engagements, translating complex requirements into manufacturable geometry, advising on tolerances, material choices, and production readiness across FDM, SLA, DLS, and metal sintering. I also lead DFMA analyses, design-to-cost studies, and cross-functional collaboration to move concepts from idea to validated production releases.

Roark Wolfe

Product Designer, 3D Designer, 3D Modeler, +2

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I am a senior mechanical engineer and independent product developer with 25+ years of hands-on 3D modeling, prototyping, and design-for-manufacture work. I specialize in SolidWorks and Fusion 360, delivering production-ready STL files and complete drawing packages for consumer products, industrial hardware, and medical devices. I work remotely on project-based engagements, translating complex requirements into manufacturable geometry, advising on tolerances, material choices, and production readiness across FDM, SLA, DLS, and metal sintering. I also lead DFMA analyses, design-to-cost studies, and cross-functional collaboration to move concepts from idea to validated production releases.…I am a senior mechanical engineer and independent product developer with 25+ years of hands-on 3D modeling, prototyping, and design-for-manufacture work. I specialize in SolidWorks and Fusion 360, delivering production-ready STL files and complete drawing packages for consumer products, industrial hardware, and medical devices. I work remotely on project-based engagements, translating complex requirements into manufacturable geometry, advising on tolerances, material choices, and production readiness across FDM, SLA, DLS, and metal sintering. I also lead DFMA analyses, design-to-cost studies, and cross-functional collaboration to move concepts from idea to validated production releases.

Available to hire

I am a senior mechanical engineer and independent product developer with 25+ years of hands-on 3D modeling, prototyping, and design-for-manufacture work. I specialize in SolidWorks and Fusion 360, delivering production-ready STL files and complete drawing packages for consumer products, industrial hardware, and medical devices.

I work remotely on project-based engagements, translating complex requirements into manufacturable geometry, advising on tolerances, material choices, and production readiness across FDM, SLA, DLS, and metal sintering. I also lead DFMA analyses, design-to-cost studies, and cross-functional collaboration to move concepts from idea to validated production releases.

Skills

Experience Level

Expert

Expert

Expert

Expert

Expert

Work Experience

Owner at Orion Structure LLC

May 1, 2018 - January 1, 2022

Delivered 3D product development and prototyping engagements for clients from startups to established manufacturers using SolidWorks and Fusion 360. Produced STL files and complete drawing packages for fabrication, rapid prototyping, and manufacturing release; managed full concept-through-validation workflow remotely. DFM/DFA analysis on consumer and industrial products; translated end-user requirements into producible geometry with clear cost and timeline guidance. Mass/performance trade studies and design-to-cost analysis; experienced communicating design tradeoffs to non-technical stakeholders.

Senior Mechanical Engineer -- Product Design at W.L. Gore and Associates

September 1, 2005 - Present

Led complex SolidWorks modeling and GD&T documentation on medical devices with tight tolerances and highly nonlinear material behavior. Drove additive manufacturing across Carbon3D DLS, SLA resin, FDM, and metal sintering for functional prototypes and design validation. Designed and released custom manufacturing tooling and fixtures with full drawing packages for fabrication and inspection. Redesigned the Thoracic Side Branch device for improved manufacturability; led cross-functional teams through design, verification, and production release.

Mechanical Engineer at Orbital Sciences Corporation

January 1, 2000 - September 1, 2005

Designed and integrated precision structural assemblies across 15 vehicle programs; produced complete drawing packages and tolerance stack-ups for flight hardware. CAD modeling of mechanisms and structural components with tight interface control; experienced designing to exacting dimensional and functional requirements.