Alessandro C.

Experience

• Mechanical Design Engineer AFC ENERGY · Self-employed Jan 2022 – Jan 2024 2 yrs Dunsfold, England, United Kingdom Mechanical Design Engineer – Hydrogen Fuel Cell Systems
  
  Led the design and development of mechanical components and assemblies for hydrogen fuel cell systems, focusing on performance, durability, and manufacturability.
  
  Designed fuel cell stacks, support structures, and mechanical systems using SolidWorks
  
  Conducted 2D/3D FEA (ANSYS 24) for structural integrity and feasibility assessments
  
  Created large assembly drawings and supported manufacturing workflows
  
  Performed engineering calculations and data analysis using Excel
  
  Participated in testing and validation of mechanical designs
  
  Coordinated with workshops and suppliers for prototyping and production
  
  Maintained technical documentation throughout the design cycle
  
  Experienced in high-performance energy systems and simulation-driven mechanical design.
• MECHANICAL DESIGN ENGINEER SPECIALIST RAYNER · Self-employed Jan 2018 – Jan 2022 4 yrs Worthing, England, United Kingdom Focused on the design and structural analysis of advanced optical medical devices, particularly lenses.
  
  Developed FEA models (ANSYS 22) for hyperelastic lens structures, integrated with optical design in ZEMAX
  
  Designed optical components and support devices (e.g. opto-durometers, lens centering systems) using SolidWorks
  
  Performed in vitro testing and materials validation for new lens products
  
  Conducted 2D/3D structural simulations and feasibility studies for design optimization
  
  Applied Design of Experiments (DOE) and response curve analysis for system refinement
  
  Managed technical data using spreadsheets and analytical tools
  
  Strong in optical-mechanical integration, FEA modeling, and high-precision medical product development.
• MECHANICAL DESIGN ENGINEER AND ANALYST PTL TECHNOLOGIES · Self-employed Jan 2018 – Jan 2019 1 yrs Shoreham-by-Sea, England, United Kingdom Provided expert consulting in the structural and dynamic analysis of engine components using advanced simulation tools.
  
  Analyzed parts like crankshafts, valve trains, gearboxes, engine mounts, and cooling systems
  
  Used 1D/2D tools (GT-SUITE) and 3D FEA (ANSYS) to model and assess performance under stress, fatigue, and vibration
  
  Integrated MATLAB routines to link GT-SUITE and ANSYS models for deeper simulation control
  
  Applied engineering fundamentals: hand calculations, contact mechanics, fluid dynamics, and nonlinear analysis
  
  Optimized complex models by identifying key variables influencing results
  
  Tools used: CREO Parametric, SolidWorks, ANSYS, MATLAB, GT-SUITE
  
  A highly technical role requiring cross-disciplinary expertise and strong problem-solving skills.
• MECHANICAL FEA AND CFD DESIGN ANALYST CERES · Self-employed Jan 2015 – Jan 2018 3 yrs Horsham, England, United Kingdom Mechanical Design & Simulation Engineer – Fuel Cell Systems
  
  Focused on advanced fuel cell design with heavy use of FEA/CFD and parametric CAD modeling.
  
  Built parametric CAD models integrated with FEA/CFD tools (ANSYS, Abaqus) for iterative design
  
  Ran detailed simulations involving nonlinear behavior, pre-stressed models, gaskets, creep, and plasticity
  
  Used hand calculations and MATLAB routines to validate and support simulation results
  
  Conducted physical testing to verify FEA/CFD outcomes
  
  Applied a top-down design approach to develop sustainable and robust fuel cell systems
  
  Managed large datasets using spreadsheets and custom analysis tools
  
  Strong in simulation-driven design, data analysis, and high-fidelity engineering workflows.
• MECHANICAL DESIGNENGINEER AND ANALYST AUTARKY AUTOMATION · Self-employed Jan 2013 – Jan 2015 2 yrs East Grinstead, England, United Kingdom Mechanical Design Engineer – Custom Machinery (Food Industry)
  
  Contract role focused on the detailed design of custom transport and handling machinery for the food and automation sectors.
  
  Designed for manufacturing: conveyors, lifting systems, motor-driven mechanisms (AC/DC), belt drives, and positioning equipment
  
  Integrated sensors and instrumentation into machinery systems
  
  Performed key engineering calculations: belt and bearing sizing, component selection (pulleys, sensors, chains)
  
  Conducted structural FEA and modal vibration analysis using ANSYS
  
  Completed tolerance stack-ups and detailed 2D mechanical drawings
  
  This role was all about precision and applying core engineering principles to create reliable, production-ready designs.
• Mechanical Design Engineer ESHMAN MEDICAL EQUIPMENT · Self-employed Jan 2011 – Jan 2013 2 yrs Lancing, England, United Kingdom Mechanical Design Engineer – Medical Devices
  
  Worked on the full development of medical equipment—from concept to launch. Started as a designer and grew into a project lead while still staying hands-on.
  
  Designed surgical tables and accessories using SolidWorks
  
  Led a small team to develop complex mechanical parts
  
  Communicated with clients and managers to define requirements
  
  Used ANSYS and CFX for FEA and simulation
  
  Handled FMEA, risk assessment, and full product lifecycle
  
  Managed project tasks and documentation with MS Project, Excel, and Word
  
  Skilled in mechanical design, simulations, and turning ideas into real, functional products.