Hammad A.

Certified SOLIDWORKS Expert (CSWE) & Prototyping Engineer. I turn ideas into functional 3D designs and engineer parts for injection molding with strict DFM checks so that a factory can sign off on them without delay. A 3D CAD model is only successful if it can be manufactured cost-effectively, assembled reliably, and passes tooling review on the first pass. As a PEC-Licensed Mechanical Engineer and Certified SOLIDWORKS Expert (CSWE), I engineer plastic parts, enclosures, and mechanical assemblies for flawless transition into mass production. Trusted to engineer tooling-ready hardware and DFM-optimized components for global brands and startups, including projects for Spotify (Spotify x Liquid Death) and Swellframe. CORE ENGINEERING CAPABILITIES ⚙️ Design for Manufacturing (DFM) & Injection Molding • Moldability Optimization: Execute draft angle analysis, enforce uniform nominal wall thickness, and place parting lines for clean tool release • Structural Engineering: Design ribs, gussets, bosses, cored-out sections, and snap-fit joints to maximize part rigidity and streamline assembly • Defect Prevention: Eliminate sink marks, knit/weld lines, air traps, and warp/shrinkage risk through proactive geometry optimization • Tooling Feasibility: Mitigate undercuts, verify slider and lifter clearances, and optimize side-actions to directly lower mold fabrication costs • Polymer Selection: Recommend optimal resins (ABS, PC, PP, POM/Acetal, Nylon PA, TPE) tailored to your product's mechanical and thermal demands 🧩 Plastic Part, Enclosure & Mechanical Design • Custom Enclosures: Design rugged, aesthetic housings for IoT devices, consumer electronics, and PCBs with clean fitment • Mechanical Systems: Engineer and optimize moving assemblies, linkages, hinges, gear trains, and structural mounting brackets • Fastener & Hardware Integration: Integrate heat-set threaded inserts, self-tapping screws, O-rings, and gasket seals for reliable sealing and assembly • Ergonomics & Industrial Design: Balance ergonomic, user-centric curvature with strict internal mechanical clearances 🖨️ In-House 3D Printing & Physical Prototyping • Rapid Prototyping: In-house functional FDM printing for fast-turnaround physical design verification • Hands-On Validation: Physical fit-checks of snap fits, screw bosses, thread engagements, and assembly tolerances • Proof of Concept (PoC): De-risk mechanical assemblies with physical parts before committing to expensive tooling handoffs 📐 Production CAD Modeling & 2D Manufacturing Drawings • Native SolidWorks: Build robust, fully editable parametric feature trees and complex surface models • Neutral File Formats: Export high-precision STEP, IGES, Parasolid (x_t), and 3D printing STL file packages • 2D Technical Drawings: Create fully dimensioned engineering drawings with GD&T (ASME Y14.5), fits, and manufacturing tolerances • Vendor Handoff Packages: Deliver comprehensive Bill of Materials (BOM), exploded assembly views, and manufacturing instructions 🔄 Reverse Engineering & Mesh-to-CAD • STL to STEP Conversion: Transform 3D scan data, mesh geometries, or physical parts into clean, editable parametric CAD • Dimensional Inspection: Rebuild legacy components while maintaining critical mounting interfaces and functional tolerances CLIENT SUCCESS HIGHLIGHTS "Hammad designed the enclosure for our e-ink display, and did an outstanding job. He took our vision for a clean, wall-worthy product and turned it into a finished design..." — Verified Client ($2,700 Enclosure & DFM Contract) "Hammad did a great job optimizing our design for injection molding. He clearly understood the manufacturing requirements and applied the necessary draft angles while maintaining the integrity of the original design." — Verified Client (Injection Molding Design Optimization) "Great Designer, got the job done to the exact millimeter as required." — Verified Client (Li-ion Battery Casing & Mechanical Fit) SOFTWARE & TECHNICAL TOOLKIT • Primary CAD: Dassault Systèmes SOLIDWORKS (CSWE Certified: Surfacing, Sheet Metal, Weldments, Mold Tools) • Manufacturing: Injection Molding Tooling, FDM 3D Printing, CNC Machining, Sheet Metal Fabrication • Standards: GD&T, ASME Y14.5, ISO Fits & Tolerances Have an initial concept sketch, PCB STEP file, 3D scan, or existing CAD file that needs DFM optimization? Send it over for a complimentary manufacturability review and a practical roadmap to production.