Ben N.

I help companies turn consumer-product concepts and prototypes into production-ready designs for injection molding, electronic enclosures and sheet metal fabrication. With 30+ years of product development and Design for Manufacturing (DFM) experience, my focus is not simply creating CAD that looks correct. I design products around how they will actually be tooled, manufactured, assembled and produced reliably. REAL MANUFACTURING EXPERIENCE My experience includes products that have progressed well beyond the prototype stage: • 100,000+ units manufactured - high-volume injection molded electrical products developed from concept through DFM, tooling interaction, first-off-tool changes and production. • 5,000+ units manufactured - commercial electronic enclosure where I completed the product design, injection molding DFM and complete injection mold tool design. • Commercial sheet metal products still in production - complete fabricated mechanical products involving sheet metal DFM, mechanisms, FEA, welding, BOMs, DXF files and manufacturing drawings. • Approximately 65 electrical products developed for one long-term manufacturing client. • Approximately 20 fabricated mechanical products developed for an international access-control manufacturer. MY CORE SERVICES Injection Molding & Plastic Product Design • Injection molded product development • Plastic part design • Injection molding DFM • Wall thickness, ribs, bosses and draft • Undercut and tooling-risk reduction • Design for Assembly (DFA) • Prototype-to-production development • First-off-tool / T1 design corrections Electronic Enclosure Design • PCB enclosure design • Internal component packaging • Connector, button, LED and display integration • Injection molded electronic housings • Fastening and assembly strategy • Production-ready enclosure CAD Sheet Metal Product Design • Sheet metal DFM • Fabricated mechanical products • Welded assemblies • Mechanism development • FEA • Weight and structural optimisation • Manufacturing drawings • BOMs, DXFs and welding documentation Design for Manufacturing Consulting • DFM review before tooling • Production-readiness review • CAD review before manufacturing • Prototype-to-production assessment • Manufacturer DFM review • Assembly and tolerance review • Tooling and manufacturing-risk identification WHY MANUFACTURING EXPERIENCE MATTERS A product that works as a prototype is not automatically ready for manufacturing. Injection molding introduces draft, shrinkage, wall-thickness, ejection, tooling and assembly constraints. Electronic products require the PCB, connectors, displays, switches, wiring and enclosure to function as one mechanical system. Sheet metal products must account for bending, welding, fabrication tolerances, structural performance and assembly. My role is to identify these issues before they become expensive tooling or production problems. WHAT YOU CAN EXPECT ✔ Production-focused product development ✔ Professional 3D CAD and production-ready files ✔ Practical Design for Manufacturing advice ✔ Design for Assembly and mechanism development ✔ Collaboration with manufacturers and toolmakers worldwide ✔ Clear communication and regular project updates ✔ Fusion 360-based product development and CAD EXPERIENCE • BSc Mechanical Engineering Degree • 30+ years of product development and manufacturing experience • Upwork Top Rated Plus • ~$300K earned on Upwork • Experience from concept development through tooling and commercial production If you need an experienced Product Design Engineer / Mechanical Designer who understands DFM, injection molding, electronic enclosures, sheet metal fabrication and real manufacturing, send me details of your product, its current development stage and the intended manufacturing process.