Juan Santana

Industrial Design & Product Development | Consultant

SantanaLab • ZZP

Dec 2020 - Present • 5 yrs 5 mos

From concept to production, I’ve contributed significantly to the business growth, innovation, and custom product solutions across various industries. My experience lies in end-to-end product development, combining skills in Reverse Engineering, FEA, GD&T, testing, and prototyping. I bring a blend of analytical thinking and creative problem-solving to every project. Technically proficient in CAD modeling, Design for Manufacturing (DfM), and the use of advanced technologies, including 3D printing (FDM, SLS), CNC machining, and sheet metal fabrication. I constantly explore new tools and sustainable design methods to improve efficiency and reduce environmental impact. I specialize in delivering comprehensive design and engineering services, tailored to the unique needs of startups, small businesses, and established enterprises, ensuring manufacturable, cost-effective, and user-centered solutions.

Manufacturing Design Engineer | R&D Technician

1to1 Design • ZZP

Dec 2024 - Nov 2025 • 11 mos

Design for Manufacturing (DfM) & Product Development: • Led the design and development of mechanical components with a focus on Design for Manufacturing (DfM) and Design for Additive Manufacturing (DfAM) using SolidWorks and PTC Creo for 3D modeling, technical drawings, and assemblydocumentation. • Conducted design reviews to assess manufacturability, structural feasibility, and process constraints to support early-stage risk reduction. Additive Manufacturing & Prototyping: • Produced 30+ functional prototypes using advanced additive manufacturing technologies, including large-format FDM (BigRep, Modix, Stratasys) and SLS (EOS P385), to support design validation and engineering testing. • Evaluated AM-specific risk factors such as part orientation, support strategy, feature resolution, thermal distortion, and interlayer adhesion, providing feedback for design iteration. Process Optimization & Equipment Maintenance: • Optimized AM workflows through printer calibration, preventive maintenance, and process standardization, increasing production efficiency and reducing operational costs. Cross-Functional Collaboration & Quality Standards: • Coordinated with clients and internal teams on several R&D projects, providing technical advice and ensuring a smooth transition from Concept to Prototype, aligned with performance and manufacturing goals. • Promoted a safe and organized work environment by enforcing health, safety, and quality standards, focused on product quality compliance, and full adherence to health and safety protocols.

Advanced Manufacturing Engineer & Product Support Consultant

Honeywell • ZZP

Mar 2021 - Dec 2022 • 1 yr 9 mos

Held responsibility as Product Owner, providing engineering support in New Product Introduction (NPI/NPE) processes, improving manufacturing and assembly quality, process efficiency, and regulatory compliance in electromechanical products. • Led DFMEA, PFMEA, and MRL assessments, ensuring design-to-production readiness and risk mitigation throughout the product lifecycle. • Analyzed technical drawings and engineering documentationusing PLM systems and CAD tools (SolidWorks), and created Work Instructions for the operators in the factory using SolidWorks Composer, streamlining manufacturing workflows, assembly process, health & Safety (HSE) measures, Built in Quality (BIQ) steps, and reducing assembly time by 20%. • Executed BOM analysis and validation with Teamcenter PLM, Oracle databases, and Dassault Systèmes PLM, supporting product lifecycle management, improving supply chain efficiency, and reducing material waste and costs. • Implemented correct actions following failure analysis, achieving a 30% reduction in COPQ. • Utilized IT platforms such as Accolade, JIRA, and SharePoint to manage documentation, stakeholder communication, issue tracking, and product data. • Collaborated with cross-functional teams (mechanical, electrical, software/firmware, QA, and production) to ensure 100% on-time delivery of project deliverables. • Conducted occasional trips to the factory in Katowice, Poland, supervising on-site projects, validating manufacturing processes, and ensuring compliance with quality and production targets, while maintaining close communication with operators and the full team.