Martin

Senior Medical Device CAD & DFM Specialist

Stryker • Parttime

Apr 2026 - Present • 2 mos

Served as a Senior CAD and DFM Specialist within Stryker’s surgical equipment division. My job centered on the high-precision reverse engineering of legacy surgical instrument parts and optimizing biocompatible plastic components for medical-grade injection molding. Due to the critical nature of medical devices, I worked with ultra-tight tolerances. I reverse-engineered legacy, hand-held power tool housings and battery latch mechanisms that had worn out over years of clinical use. Using microscopic metrology data, I recreated these intricate mechanical assemblies in SolidWorks, translating them into highly precise, parametric models. I compensated for cosmetic and mechanical wear, outputting clean STEP files for high-precision CNC micro-machining and metal injection molding (MIM). For our high-volume plastic disposables and enclosures, I conducted rigorous DFM evaluations. I utilized SolidWorks to optimize wall thicknesses to prevent internal voids and sink marks, configured precise draft angles to avoid drag marks during mold opening, and designed robust mating surfaces for ultrasonic welding. I collaborated with prototype labs to validate designs via high-resolution 3D printing before final mold tooling release, creating highly detailed 2D technical drawings with complex tolerance stacks to guarantee functional assembly.

Freelance Mechanical Engineer & Injection Molding DFM Specialist

Fiverr • Freelance

Jun 2026 - Jun 2026 • 0 mos

Provided professional reverse engineering and injection molding DFM optimization services to startups, machine shops, and manufacturing companies across the USA, UK, Germany, and Canada through Fiverr and direct B2B engagements. Successfully converted worn mechanical components into production-ready STEP CAD files for CNC machining, reducing downtime for industrial equipment and agricultural machinery. Rebuilt parametric SolidWorks models from damaged parts, technical sketches, and 3D scans. Optimized plastic injection molded parts by correcting wall thickness distribution, applying proper draft angles, redesigning bosses and ribs, and eliminating molding defects such as warpage and sink marks before mold tooling. Delivered over X+ manufacturing-ready CAD projects with strong focus on precision, tolerancing, and real-world manufacturability.

Lead Product Design & Plastic DFM Engineer

Dyson • Freelance

Apr 2026 - May 2026 • 1 mo

Worked as a Lead Product Design and Plastic DFM Engineer at Dyson, specializing in complex, high-aesthetic consumer appliances. My focus was on ensuring that every molded plastic part achieved premium surface finishes while maintaining high structural strength and low manufacturing costs. I took early-stage conceptual product designs and prepared them for mass production through exhaustive SolidWorks CAD optimization. Because Dyson products rely on seamless visual lines, preventing injection molding defects like sink marks, weld lines, and warpage was paramount. I systematically analyzed wall thickness profiles, re-designed complex internal structural ribs to be 60% of the nominal wall thickness, and strategically placed ejector pin bosses to prevent cosmetic blemishes. I ran mold flow analyses to predict knit line locations and adjust gate placement, ensuring the final consumer-facing parts were perfect. I also reverse-engineered legacy motor components and impeller systems that required modification for next-generation products. I transformed worn prototype impellers into mathematically optimized parametric CAD parts, correcting rotational balance and wear-related surface erosion. I delivered production-ready STEP files and detailed technical drawing sheets with GD&T to manufacturing partners throughout the UK, Europe, and Asia.