Ireland
Mechanical Design Engineer with 10+ years of experience specialized in navigating the complexities of high-reliability medical device development, from initial concept through to design verification. My career is driven by an intense curiosity for solving ambiguous technical challenges and a passion for delivering robust, life-changing engineering solutions. Technical Leadership & Impact: Curiosity-Driven Problem Solving: I apply advanced analytical methods, including non-linear FEA and CFD, to decode failure modes and optimize injection-moulded systems. Strategic Design Oversight: Experienced in managing technical design outputs, ensuring rigorous adherence to ISO 13485 standards while leading cross-functional teams and mentoring junior engineers. Manufacturability & Risk Control: Passionate about bridging the gap between design and production through expert DFM/DFA, tolerance analysis, and comprehensive dFMEA/pFMEA management. I thrive in regulated environments where precision is paramount, leveraging a detail-oriented approach to translate functional requirements into scalable, manufacturable mechanical architectures.
Directed the design recovery of a 12-component DPI assembly, identifying critical tolerance stack-up issues that reduced scrap rates by 30% and secured a €12M production line. Managed a cross-functional team of 5 engineers, implementing a new GD&T governance framework that reduced design iteration cycles by 40%
Technical Design Authority: Served as the Technical Lead for Dry Powder Inhaler (DPI) device design and verification, ensuring all mechanical architectures met stringent functional requirements. Risk Management & Compliance: Managed dFMEA and pFMEA throughout the design outputs phase to mitigate production risks and ensure full alignment with regulatory standards. Advanced Characterization: Led the design characterization, axial/torque testing, and analysis of complex injection-moulded components to validate mechanical integrity. Strategic Verification Planning: Developed and executed comprehensive Design Verification (DV) and Clinical Design Verification testing plans for both DPI and surgical instrumentation. Rapid Iteration & Prototyping: Directed rapid prototyping cycles for products and high-precision fixtures, accelerating the evaluation and iteration of design concepts. Documentation Governance: Held responsibility for the drafting, technical review, and approval of critical design documentation, maintaining high standards of design traceability.
Acceptance testing of qualified hardware for flight including functional, vibrational, flow and cleanliness. Increased piece part cleaning capacity 8 fold and improved in piece part serialisation. Decreased cycle time and reduced setup difficulty of complex build operations. Diagnosis, rebuild and elimination of FOD in a high purity flow testing machine. Introduced lean principles to work stations and workflows. Created and introduced new processes to AS9100 Introduced new technologies to characterise precise parts for assembly.
• Lead Engineer in design & validation of products to business requirements • Assembly and reverse assembly of products for analysis and report writing. • Testing, data recording and reporting of product performance. • Calculation & specification of mechanical, pneumatic, and electrical components of product for special application environments along with supporting documentation • Collaborative CAD design of new product for individual customer requirements, eliminating non-critical design elements and focusing on applicable testing. • Manufacturing support, problem solving and RCAs. • Validation testing of critical components for production use, routine disassembly and inspection of product for damage and potential failure modes. • Flow testing of products to capture flow characteristics. • Material qualification against hydrogen embrittlement to ISO and TPED standards • 3D printing: Plastic selective laser sintering (SLS), fused deposition modelling (FDM) and wire arc additive manufacturing (WAAM)
Calf Rearing, Cow herding and machine driving.
Solidworks company implementation & training • Aluminum profile design optimisation using FEA and mechanics • Prototyping, testing and evaluation of existing product upgrades • New product training for field engineers • Investigation of test and product failures and establishing root cause of failure • Product installation and repair brainstorming with field engineers • New product manufacturing zone build, production run testing, validation and in Birmingham • New product patent feasibility study • Product development of new product ranges to market o Project planning and management o Concept development with suppliers o Prototype design, machine, 3D printing, install, function, durability and functional testing o Ergonomic Study: Product testing using force gauge & accelerometers