Greater Bristol Area, United Kingdom
As a Lead Design Engineer with over a decade of experience, I thrive at the intersection of mechanical design and innovative product development. I’ve had the privilege of leading projects that push the boundaries of engineering, such as the Dyson Supersonic r™ and Dyson Airstrait™, recognised among the top innovations in the industry. Specialising in product design, CAD & 3D modelling, and prototyping, I combine a hands-on approach with a commitment to driving high-impact results. My expertise spans design for manufacture and assembly, risk management, and tolerance stacking, ensuring that each product not only meets but exceeds performance and quality standards. Throughout my career, I’ve collaborated with cross-functional teams to deliver products that are both groundbreaking and consumer-friendly, while managing complex technical challenges. Leading and developing teams is a key passion of mine. I’ve successfully managed and mentored diverse groups of engineers, fostering a culture of high performance and collaboration. My focus on continuous improvement has led to the implementation of quality training programs and peer-review systems, which have enhanced both technical skills and operational efficiency. I believe in clear goal-setting, continuous feedback, and professional development, ensuring my teams consistently deliver innovative solutions that align with company objectives. I’m passionate about combining cutting-edge technology with practical, user-centered design, and am always looking for opportunities to collaborate on projects that challenge the status quo. Let’s connect if you want to discuss design engineering, product development, or emerging technologies.
Mechanical design and integration expert, leading five key projects that have significantly influenced Dyson’s future product range in the Hair Care category: • Spearheaded the design of a novel attachment, resulting in being named inventor on two patents. • General Assembly owner for a new product format, leading a sub-system team of 5 engineers. Responsible for tracking KPIs (size, weight) and managing risk through DFMEA using Plato E1ns. • Technical lead for a new heater format, guiding a team of 4 engineers through the TRL process, prototyping, and testing to ensure product viability in target environments. Improved yield and reduced costs on the latest patented heater technology for the Dyson Supersonic™, which is 20% lighter and 30% smaller than its predecessor. • Line manager for 5 engineers, driving performance development, coaching, and goal-setting to foster individual and team success. • Completed a Systems Engineering Fundamentals Course, supporting the delivery of Dyson’s most power-dense products, including the Dyson Airstrait™ and Dyson Supersonic™, both top-rated by consumers.
Worked in an integration team to bring early-stage projects to maturity, completing a 9-month secondment in the Dyson Digital Motors team, where I engineered the fastest Dyson motor with a line capacity of 7m per annum: • Engineered the Dyson Airstrait; managed the arm and hinge assembly from specification to tooling delivery, contributing to its recognition as one of Time magazine's best inventions of 2023. • Led weekly calls with international suppliers to ensure on-time motor frame sample delivery, resolving material, tooling, and quality issues while reporting progress for budget and timeline alignment. • Designed an alternative bearing mount to prevent heat damage while preserving motor performance; currently in the patent process, showcasing innovation and technical expertise. • Developed designs for low-cost, high-volume manufacture, leveraging expertise in DFM, DFA, FEA, and tolerance stacking to deliver effective designs, prototypes, and jigs. • Operated cross-functionally to ensure compliance, safety, reliability, cost-effectiveness, and sustainability in all part requirements. • Mentored colleagues and provided technical expertise in regular reviews, fostering a high-performing team culture.
Joined Dyson’s New Product Development Personal Care category, specialising in technical delivery across mechanical, electrical, and systems engineering while contributing to user interactions, accessories, structures, and integration across 10 projects: • Led the UI sub-system for Dyson Supersonic, achieving an 80% reduction in button assembly production times and enhancing the repairability of returned products. • Delivered the Dyson Supersonic stand to global markets with a 40% cost reduction in the bill of materials (BOM) while maintaining specifications and design integrity. • Managed product control systems on 2 cutting-edge technology projects and electronic and mechanical integration on 8 new products. • Directed Design Failure Mode and Effects Analysis (DFMEA) activities and requirement creation, ensuring comprehensive technical risk management and timely project delivery. • Conducted high-level reviews with the senior leadership team and James Dyson, driving strategic decisions through effective design presentations.
Consultant designer managing full design responsibilities across diverse markets, directly liaising with clients and manufacturers in a fast-paced environment: • Delivered over 30 projects, consistently meeting deadlines and client requirements while honing design skills and adapting to various industry demands. • Generated and developed award-winning products, including those recognised by the Design Council Spark Award (2016), Junior Design Award (2018), European Product Design Award (2019), and A’ Design Award (2021). • Visualised client ideas through sketching, CAD, and rendering, creating functional prototypes that contributed to commercial success, including notable products like the Orb bike bottle and Rockit Rocker. • Created captivating presentation materials to effectively communicate design concepts and engage clients throughout the project lifecycle.
Contributed to the clothing and sports apparel department by creating graphic designs for newsletters and web platforms, while assisting with social media marketing: • Collaborated within a small team to develop engaging graphic content. • Enhanced skills in Adobe InDesign, Photoshop and Illustrator. • Gained insights into branding and advertising strategies, improving overall graphic design abilities. • Met tight deadlines for triweekly newsletters, demonstrating effective time management. • Learned about sports apparel materials and construction techniques. • Understood the impact of social media on branding and advertising, optimising its use.
Worked in the design studio to create concepts and visualisations for new accessory and lighting product ranges, gaining exposure to traditional Moroccan craftsmanship: • Accelerated concept generation process, enhancing design efficiency. • Acquired proficiency in Rhinoceros 4.0 CAD software. • Learned techniques from traditional Moroccan craftsmen, enriching design knowledge. • Collaborated with interior designers to create unique designs for various settings, including restaurants and hotels.