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Design engineer specialising in mechanical design, 3D CAD, simulation, and project delivery.

Also have significant experience in systems engineering, workflow development, hardware/software interfacing, fabrication, and DFM optimisation.

High proficiency in SolidWorks.

Professional Experiences

Senior mechatronics engineer in charge of productising modular robotics platform. Matured the design from a prototype to a commercial product, and optimised design for high volume manufacturing.

• Led the transition from SolidEdge to Solidworks for CAD design.

• Introduced processes for engineering data storage, version control, and change management.

• Collaborated with a multidisciplinary team to deliver the company’s first product shipment to the client on time

Designer of the “Aquacare”: complex air abrasion tool for dentists. Led the 3D designing and testing to produce a small and functional machine. Optimised for outsourced high volume manufacturing; led the production handover.

• Prepared CAD models, and technical drawings for injection moulding, fabrication, and sheet metal work.

• Coordinated with a global team of electronics and software engineers to design the product.

• Coordinated with manufacturers to prototype and arrange the production.

• Responsible for technical documentation, 3D assemblies, technical drawings for productions.

• Trained staff on assembly.

• Took initiative in introducing 3D printing and CNC machining to the company’s prototyping tools, which have become an integral part of the iterative design process.

• Created and optimized workflows for in-house FDM printing, and SLS, SLM, SLA prototyping from external suppliers.

• Created automated test jigs/fixtures. Conducted tests and carried out data gathering and analysis to improve/validate designs.

• Project Log: https://www.maheemal.com/portfolio-content/design-and-development-of-aquacare

Provided design engineering, finite element analysis and 3D CAD expertise to clients. Developed systems from concepts to practical solutions.

• Rendered designs practically feasible by successfully addressing such challenges as limited real-estate and suppliers.

• Took charge of developing skids converting P&ID diagrams into CAD models for Cambridge Fluid Solutions.

• Project Log: https://www.maheemal.com/portfolio-content/development-of-a-chemical-storage-skid

Technical Projects

ROS integrated 6 axis robotic arm that I designed and built with 3D printed and machined parts.

• Improved the design of the open-source “BCN3D Moveo” arm to add a 6th rotational axis.

• Created a URDF (Unified Robotic Description File) of the arm and integrated to ROS.

• Used RVIZ and Gazebo to produce intelligent movement.

• Project Log: https://www.maheemal.com/portfolio-content/6-axis-robotic-arm

Created a chessboard that recognises user input and moves the opponent’s pieces automatically.

• Created a matrix of REED switches to mount underneath the chessboard and used magnetised chess pieces to recognize piece movements by the player.

• Created an XY plotter equipped with an electromagnet, mounted underneath the chessboard to move the PC controlled chess piece accordingly.

• Designed and produced the circuit boards to interact between the Raspberry Pi and all the inputs outputs such as REED switches, stepper motors, and microswitches.

• Used Python, and Deep Fritz chess engine to recognise and interpret the move by the player, calculate the response and calculate travel path for the PC player piece.

Created a CAD model an aircraft tail wing section, and an FEA model/simulation to predict the stress/strain/deflection under different load conditions.

• Created a CAD model of an aircraft wing from the manufacturer’s technical drawings (complex stretched skin on a two-spar structure).

• Used ANSYS FEA to simulate stress, strain, and deflection on an aircraft wing.

• Used strain gauges to validate and further calibrate the mathematical models built.

• Project Log: https://www.maheemal.com/portfolio-content/stress-analysis-of-a-two-spar-wing

• Learned V+ programming language to produce 6 axis GCODE for the arm.

• Designed and produced a gripper attachment for the arm (3D Printing, CNC, Electronics).

• Wrote a program that spells a given word by picking, manipulating, and placing blocks with letters marked on each face.

Education

Full List: https://www.maheemal.com/education

Interests

• Classical musician on the violin

• BHPA certified paraglider pilot

• Hobbyist PCB designer with an interest in low power embedded systems design