Simulation & Analysis team (Associate Principal Engineer)As the Thermal/Mechanical Lead, I oversee a compact team of structural, thermal, and aero engineers dedicated to validating the performance of Dyson motors, heaters, and battery packs. My responsibilities include:• Managing the team's engineering activities to meet performance, reliability, and cost expectations within planned project timelines.• Collaborating with project management teams to review design concepts and allocate resources effectively for a robust project timeline.• Serving as the Simulation and Analysis - Motors Thermal Lead, ensuring standards for thermal simulation and testing are upheld across Dyson Motor Simulation and Analysis teams in the UK, Singapore, Malaysia, and the Philippines.• Innovatively contributing to the development of an overmould motor design for power-dense motors, resulting in a patent (Patent: 2610477).Initiating process improvements:• Contributing to the development of in-house conjugate heat transfer simulation capabilities for motor thermal analysis, encompassing both steady state and transient simulations. This capability allows for the early resolution of potential thermal issues before prototypes are built.• Created 1D thermal models in Matlab Simscape and Excel, optimising the efficiency of thermal analysis for initial motor designs. This approach significantly expedites thermal feasibility studies, reducing completion times from days to mere hours in certain cases.• Leading the development and validation of an Aero/Thermal semi-automated motor test rig.

As the Mechanical Lead for a new motor project (Dyson V10 – V15 products), I perform the following key responsibilities:Conducting Design Failure Mode and Effect Analysis (FMEA) to enhance design robustness.• Managing all mechanical engineering activities to ensure the project aligns with product performance, reliability, and cost expectations within the designated timeline.• Communicating project results and status clearly to a wide range of project members and senior management.• Compiling comprehensive system specifications to guarantee adherence to engineering design and overall performance criteria.• Reviewing component, assembly and tolerance stack drawings to uphold design integrity and quality standards.

Motors Research & Development (Senior Mechanical Engineer)Mechanical Engineer: Responsible for providing a motor sub-system mechanical solution (Dyson V6 – V8 & Supersonic) which is reliable and fit for purpose. Duties:Researching and developing innovative, high-value intellectual property solutions.• Creating simple mathematical models for preliminary performance predictions to inform design decisions.• Designing and conducting investigative tests to validate performance.• Conducting detailed analysis of mechanical systems using FEA software, covering Rotordynamic, structural, and thermal aspects.• Selecting materials and manufacturing processes.• Generating component and assembly drawings using CAD software (NX).• Performing Tolerance Stack Analysis and, where appropriate, utilizing Statistical tolerancing.• Analysing validation test results using statistical methods to ensure motors meet specified requirements.• Writing and presenting comprehensive reports to communicate findings across team functions and management levels.

Motors Research & Development (Mechanical Engineer)Mechanical Engineer: Responsible for developing validation tests and support manufacturing. Duties:• Design, build and assemble test rigs (I am a skilled machinist).• Produce test reports.• Develop robust test methods, working closely with reliability teams.• Manufacturing support (I spent a total of 12 months between Japan and Singapore, supporting the validation of a fully automated motor assembly line).

Worked as a volunteer mechanical engineer to help design and develop an emergency ventilator to help fight Covid-19 in 3rd world countries.

Consulted on the design and produced engineering drawings of a product, which the company wanted to bring to market.