Moustafa E.

Experience

• Senior Mechanical Design Engineer Layn · Full-time Mar 2025 – Present 8 mos Egypt • Led the product design of CNC Concrete 3d Printers using Solidworks.
  • Designed and developed mechanical systems and components for CNC concrete 3D printers, from concept to production.
  • Performed DFMEA (Design Failure Mode and Effects Analysis) to identify and mitigate potential design risks and ensure product reliability.
  • Created detailed manufacturing drawings using GD&T (Geometric Dimensioning and Tolerancing) to ensure precision and manufacturability of components.
  • Conducted FEA (Finite Element Analysis) and other simulation methods to validate designs, ensuring structural integrity, performance, and reliability of printer components under various loading conditions.
  • Performed comprehensive testing and validation of prototypes and production machines, identifying and resolving mechanical issues to optimize performance and print quality.
  • Collaborated with cross-functional teams, including electrical, software, and materials engineers, to integrate mechanical designs and ensure seamless system operation.
  • Applied DFM (Design for Manufacturing) and DFA (Design for Assembly) principles to optimize designs for efficient and cost-effective production.
  • DFMEA "Design Failure Modes and Effects Analysis" Preparation.
  • Managed the selection and specification of materials and manufacturing processes, performing mechanical parts sourcing to meet design requirements and cost targets.
  • Generated BOMs (Bills of Materials) and developed other technical documentation for manufacturing and assembly.
• Research & Development Engineer 3D Scales · Full-time Oct 2015 – Oct 2017 2 yrs Lebanon • Invented a new System for continuous dlp 3d printing using liquid matrix support “Patent number: 10232552”.
  • Designed 3D machines’ mockups using Solidworks.
  • Supported Chemical department team on resin’s formula development to achieve optimal in-house resin.
  • Performed DOE to optimize research process and evaluate the most contributing parameters to optimal 3d print.
  • Performed Root Cause Analysis to solve early failures of 3d printed models by implementing a fishbone diagram and 5 Whys.
  • Collaborated with software development team on development and optimization of a new 3d printing software for Sequential & Continuous 3d printing methods resulting in increased reliability and performance of the 3d printer.
  • Prepared 3d models for 3d printing using Materialise Magics Software.
  • Sourced different manufacturers for prototype parts manufacturing.
  • Hands-on experience with different in-house -3D Systems- 3d printers “Polyjet, SLA, DLP, CJP and FDM”.