A hands-on engineer who can own difficult workstreams, raise the quality of decisions, and operate across engineering, product, manufacturing, suppliers, and leadership.
Senior Mechanical Engineer / Product Design + Development
I turn ambitious product ideas into hardware teams can build, test, and scale.
I move physical-product programs from ambiguity to controlled execution—defining requirements, structuring architecture, resolving the physics, creating the design, building the evidence, and coordinating the interfaces that determine performance, cost, reliability, and manufacturability.
North County San Diego. Open to senior, staff, and technical-lead opportunities plus select consulting engagements.
8+ yearsMechanical engineering + product development
5 yearsHigh-reliability aerospace R&D
Since 2023Independent product consulting
B.S.M.E. + CSWPEngineering foundation + CAD certification
Full lifecycleDefinition through controlled release
What I bring to a team
Senior-level judgment that stays connected to the hardware.
The strongest contribution of a senior engineer is not simply more geometry. It is better problem framing, better technical decisions, faster learning, and reliable ownership from the first assumption through the released definition.
Direct senior capacity that can define the work, execute the engineering, expose risk early, and leave behind a product and technical record the organization can continue using.
Frame the right problem
Turn incomplete product intent into use cases, requirements, interfaces, constraints, credible alternatives, and a risk-led development plan.
Decision-ready product definitionResolve the whole system
Connect user experience, mechanisms, structures, thermal and fluid behavior, electronics packaging, manufacturing, cost, and service instead of optimizing one part in isolation.
A coherent product architectureMake decisions defensible
Use first-order physics, CAD, tolerance analysis, FEA or CFD, prototypes, and targeted tests at the level of fidelity the decision actually requires.
Evidence-bounded engineering choicesStay with the details
Carry the reasoning into parametric geometry, materials, interfaces, GD&T, drawings, BOM structure, supplier reviews, inspection, and controlled release.
Buildable, inspectable definitionImprove what already exists
Diagnose failure, cost, reliability, performance, assembly, or service problems without quietly transferring risk somewhere else in the product.
Corrective direction with system awarenessLead across boundaries
Communicate assumptions and tradeoffs clearly, align cross-functional stakeholders, preserve decision history, and keep technical work connected to program priorities.
Faster execution with less ambiguityProduct design + development
The whole product—not just the part.
Exceptional hardware comes from treating user needs, industrial-design intent, engineering, manufacturing, validation, and business constraints as one development system.
Discover + Define
Align user needs, business goals, use cases, product requirements, constraints, and the evidence required to make the next decision.
Architect
Structure the product, interfaces, technologies, and mechanical concepts. Compare credible directions before detail makes change expensive.
Design
Resolve mechanisms, housings, ergonomics, surfaces, packaging, materials, fastening, tolerances, assembly, and service as one system.
Prototype
Build the minimum useful prototypes—from fast fit studies to functional hardware—and use each iteration to answer a defined question.
Validate
Test performance, reliability, environmental exposure, misuse, usability, and critical interfaces against explicit acceptance criteria.
Industrialize
Complete DFM/DFA, drawings, BOM structure, supplier reviews, inspection planning, pilot-build support, and production change control.
Design standard
Every choice should improve the product as a whole: how it works, feels, assembles, survives, costs, ships, services, and scales.
Explore the full capabilityExperience outline
Broad product experience, backed by rigorous mechanical depth.
The categories vary. The responsibility is consistent: understand the product, resolve the system, and leave the team with a design it can build and improve.
Aerospace + advanced communications
Owned mechanical design and analysis details in cross-functional R&D, developing high-reliability hardware under coupled thermal, vibration, structural, modal, packaging, manufacturing, and configuration constraints.
Independent product development
Translate incomplete ideas and physical interfaces into architectures, parametric CAD, calculations, prototypes, simulation, drawings, and supplier-ready technical packages across a wide range of products.
Advanced equipment development
Lead complex electromechanical workstreams from requirements and architecture through detailed design, reviews, release, supplier coordination, troubleshooting, and validation planning.
Consumer + human-centered products
Ergonomics, body-fit and freeform geometry, intuitive interfaces, durable touchpoints, product-family logic, and practical user assembly.
Electromechanical products
Displays, electronics, power components, thermal paths, cable routing, enclosures, sealing, fastening, assembly, and service access.
Industrial + performance hardware
Mechanisms, structures, flow paths, thermal behavior, acoustics, harsh environments, maintainability, and supplier-ready fabrication.
Aerospace + high-reliability systems
Coupled structural, thermal, vibration, modal, packaging, configuration, documentation, and cross-disciplinary interface constraints.
Where I add leverage
Resolve the decisions that determine whether the product succeeds.
The best engineering work makes the product clearer, the learning faster, and the path to production less fragile.
The product opportunity is clear, but the requirements and architecture are not.
I translate intent into use cases, measurable requirements, system boundaries, concepts, and a development plan the team can act on.
Form, function, cost, and manufacturing are pulling the design in different directions.
I connect industrial-design intent with mechanical performance, packaging, materials, assembly, service, and production realities.
The prototype proves the idea, but it is not yet reliable, repeatable, or scalable.
I identify the risks that separate a promising build from a production product, then structure the next design and validation loops around them.
A mature product needs better performance, lower cost, or a decisive failure resolution.
I isolate the real drivers, compare corrective options, and improve the design without quietly shifting risk into reliability or service.
Core capabilities
Senior product-development ownership at the level the program needs.
I can lead a complete mechanical workstream, join an established product team, or resolve a focused technical problem without losing sight of the product around it.
01
Product Design + Development
Complete mechanical product development from early definition and architecture through validation and production launch.
Explore capability 02Mechanical Architecture + Mechanisms
System layouts, motion, force, constraint, interfaces, purchased components, and robust mechanism design.
Explore capability 03CAD, Surfacing + Design Definition
Parametric CAD, product surfaces, complex assemblies, GD&T, tolerances, drawings, and editable design intent.
Explore capability 04Prototyping, Test + Validation
Purpose-built prototypes, fixtures, acceptance criteria, test plans, root-cause learning, and corrective iteration.
Explore capability 05DFM, DFA + Production Readiness
Process selection, assembly strategy, supplier reviews, inspection, release packages, and pilot-build support.
Explore capability 06Troubleshooting + Product Improvement
Failure analysis, performance optimization, reliability, serviceability, value engineering, and cost reduction.
Explore capabilitySpecialist depth
Advanced tools, applied in service of the product.
CAD, surfacing, analysis, reconstruction, and prototyping matter when they sharpen a decision, reduce risk, or move the hardware closer to a successful release.
PRODUCT GEOMETRY / 01
Surface + Product Geometry
Freeform surfaces, body-fit geometry, reflection quality, gaps, interfaces, and manufacturing-aware product definition.
Explore capabilityPROTOTYPE / 02
Additive Prototyping
Functional prototypes, fit-check models, insert strategy, fixtures, and disciplined build-test-learn iteration.
Explore capabilityMECHANISMS / 03
Mechanisms + Precision Motion
Motion architecture, force paths, bearings, gears, guides, linkages, actuation, holding behavior, and wear.
Explore capabilityANALYSIS / 04
Structural Analysis + FEA
Load paths, restraints, stiffness, stress, fatigue, vibration, and simulation with explicit assumptions and checks.
Explore capabilityRECONSTRUCTION / 05
Mesh to Design-Intent CAD
Supplied mesh reconstruction, interface recovery, deviation-aware decisions, and clean parametric geometry.
Explore capabilityTHERMOFLUIDS / 06
Flow, Thermal + Acoustics
Pressure loss, velocity, heat, expansion, acoustic treatment, packaging, and manufacturable internal flow paths.
Explore capabilityConceptual engineering schematics · not client hardware, analysis results, or project evidence
Representative product terrain
Different products. The same standard of execution.
Experience spans consumer, commercial, industrial, automotive, biomechanical, electromechanical, and aerospace hardware. These anonymized summaries show the range without exposing client identities or proprietary geometry.
Manual Lift, Tilt + Adjustment Systems
Design mandateUnify lift, tilt, guidance, holding, and safeguarding around a controlled mechanical platform.
Synchronized screw-drive platforms, thrust-bearing load paths, guided telescoping structures, guarded motion, hand-crank inputs, and variant-specific tilt architectures developed toward supplier-controlled definition.
High-Temperature Exhaust + Acoustic Systems
Design mandateBalance attenuation, pressure loss, hot-gas behavior, thermal growth, fabrication, and service access.
Large-flow silencer and duct architectures balanced across acoustic attenuation, engine backpressure, hot-gas velocity, thermal expansion, packaging, drainability, service access, and fabrication constraints.
Pulsation-Control Pressure Hardware
Design mandateCreate a credible pressure-boundary and flow-path architecture that can advance through staged validation.
Concept development for high-pressure discharge damping, including pressure-boundary architecture, modular labyrinth flow paths, closure and preload options, structural and fluid analysis, prototype planning, and hydrostatic-test strategy.
Brewing + Process-Control Equipment
Design mandatePackage power, control, wiring, thermal access, assembly, and service into one manufacturable product.
Touchscreen controller packaging spanning dual-voltage product architecture, power and relay integration, protective devices, internal supports, cable management, thermal access, serviceability, and additive enclosure production.
Retention, Ratcheting + Locking Systems
Design mandateRecover the mechanism intent, then control engagement, retention, wear, tolerance, and assembly risk.
Physical-hardware evaluation and parametric reconstruction of compact locking mechanisms, with emphasis on pin retention, engagement geometry, tolerance sensitivity, assembly sequence, wear paths, and robust corrective architecture.
Vehicle Surfaces + Performance Hardware
Design mandatePreserve surface quality and vehicle fit while resolving fastening, airflow, heat, and manufacture.
Custom exterior components and performance parts developed around vehicle-interface recovery, high-quality surface continuity, controlled fit-up, fastening, airflow and thermal constraints, manufacturability, and finish-critical geometry.
Foot Orthotics + Body-Fit Geometry
Design mandateTranslate variable human geometry into controlled surfaces, thickness, interfaces, and production intent.
Fit-driven freeform products translated into controlled CAD using surface reconstruction, offsets, variable thickness, blend strategy, interface definition, and manufacturing-aware geometry for individualized physical use.
Modular Track + Interlocking Products
Design mandateCreate repeatable interlocks and a scalable part family across many user-built configurations.
Large modular assemblies developed around repeatable interlocks, smooth geometric transitions, nesting, stiffness, scalable part families, configuration control, and reliable user assembly across multiple layouts.
Development method
Clear decisions. Fast learning. Fewer expensive surprises.
The sequence changes with product maturity and risk. The discipline does not: define the right problem, compare real alternatives, test the dangerous assumptions, and preserve the reasoning behind the design.
- 01
Define
User, business, technical, and manufacturing requirements.
- 02
Diagnose
Physics, interfaces, risks, unknowns, and the fastest useful learning.
- 03
Generate
Multiple concepts, first-order calculations, and transparent tradeoffs.
- 04
Develop
CAD, materials, tolerances, components, prototypes, and documentation.
- 05
Validate
Risk-focused tests, design correction, and requirements-based verification.
- 06
Release
Drawings, BOM, suppliers, inspection, pilot builds, and change control.
Engineering Lab / Eight live tools
Make the first calculation visible.
Transparent engineering calculators for fits, joints, beams, linkages, shafts, springs, and tolerance decisions—each with an explicit model boundary and live diagram.
Role + engagement fit
Where I can create the most leverage.
Strong fit
- Senior, staff, or technical-lead role with meaningful product ownership
- New product definition, mechanical architecture, or complex development
- Industrial-design-to-engineering or prototype-to-production transition
- Defined consulting workstream requiring direct senior execution
Usually not a fit
- Brand or styling work without engineering scope
- Source geometry without clear ownership or authorization
- Requests for unpaid detailed design work
- Programs without realistic development resources
Role or product inquiry
Bring me the product, the program, or the difficult decision.
For employment conversations or consulting work, share the non-confidential context, current stage, and the ownership you need. I will respond directly.