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Daniel M.

Senior Mechanical Engineer

Spotsylvania Courthouse, United States

Global rank:

4,604 / 131,936

Skill pts: 10

ANSYS Casting CNC Machining Machining Mechanical Engineering

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About

I am a Senior Mechanical Engineer with 15 years of experience specializing in the design and development of high-precision machines, hybrid manufacturing system integration, and metallurgical engineering. I focus on practical mechanical engineering solutions to enhance machine architecture, improve rigidity, optimize thermal behavior, and reduce vibration across different industrial equipment. I take pride in ensuring a smooth transition from concept to production with powerful tools like SolidWorks and ANSYS.

Experienced in the design, validation, and optimization of CNC machining centers and hybrid DED platforms, with proven contributions to DMG MORI’s LASERTEC Hybrid Series and Hurco’s VMX/VCX systems. Demonstrated capability in modal and thermal-structural analysis, chatter-reduction research, and digital-twin calibration for predictive maintenance. Skilled at coordinating global R&D efforts across Japan, Germany, and the U.S., ensuring consistent engineering standards and manufacturability across multi-site development programs.

Grounded in Metallurgical Engineering, combining expertise in casting design, heat treatment, and microstructure–performance correlation. Proficient in ProCAST simulation for mold filling, solidification, and residual-stress prediction, applying results to enhance material stability and machining accuracy. Experienced in optimizing alloy selection, thermal-cycle control, and defect prevention for cast and welded components used in precision-machinery assemblies.

Thank you for taking the time to consider my profile. With my background in mechanical design, CNC machine optimization, and hybrid manufacturing, I’m excited about the chance to bring my expertise to you. I’m confident I can offer valuable insights and help drive the success of your projects. I’d love the opportunity to discuss how I can contribute and look forward to working together.

Portfolio

Experience

Senior Mechanical engineer DMG MORI USA · Full-time Jan 2019 – Oct 2025 6 yrs 9 mos Davis, CA, United States I worked on designing and improving both hybrid additive-subtractive machines and high-precision 5-axis machining centers. My work focused on mechanical design, system integration, vibration and thermal stability, and creating reliable engineering documentation for production and automation teams.
Mechanical Engineer Hurco Companies · Full-time Jun 2013 – Dec 2018 5 yrs 6 mos Indianapolis, IN, United States I helped develop high-precision machining centers, improving frame stiffness, accuracy, and reliability. I supported prototype builds, testing, GD&T reviews, and coordinated CAD and PDM workflows to keep designs consistent across product lines.
Mechanical Engineer Associated MetalCast · Full-time Jun 2010 – May 2013 2 yrs 11 mos Oxford, AL, United States I helped develop high-precision machining centers, improving frame stiffness, accuracy, and reliability. I supported prototype builds, testing, GD&T reviews, and coordinated CAD and PDM workflows to keep designs consistent across product lines.

Education

Missouri University of Science and Technology Master of Science, Mechanical Engineering, 3 2007 – 2010
Missouri University of Science and Technology Bachelor of Scence, Metallurgical Engineering, 4 2003 – 2007

Other experience

Independent Research – Friction Stir Welding (FSW) and CNC Integration I’ve studied how friction stir welding can be integrated into CNC platforms to improve joint strength, reduce distortion, and enable multi-material manufacturing. My work focused on tool design, heat-generation behavior, fixture requirements, and how FSW heads can be adapted to CNC machine frames with proper force control and thermal management.

Licenses & Certifications

Mechanical Engineering TestDome Sep 2021 – Present