Mohamed R.
Senior Mechanical Designer | DFM & Tooling Consultant
Cairo,
Egypt
Global rank:
12,525
/
122,146
Skill pts: 5
About
I am a senior mechanical and industrial design engineer with over 20 years of hands-on experience in product design, tooling, and manufacturing systems.
My work focuses on design for manufacturing, where ideas are shaped with real production constraints in mind—materials, tolerances, tooling limits, cost, and reliability. I have designed and reviewed hundreds of molds, dies, and production components used in plastic injection molding, high-pressure die casting, sheet metal forming, and aluminum extrusion.
I work comfortably at the intersection of design, production, and decision-making—supporting companies that need designs that actually survive the factory floor. My role is often to simplify complex designs, eliminate manufacturing risks early, and reduce iterations, cost, and time to market.
I collaborate remotely with global teams and offer flexible, part-time consulting for concept development, DFM reviews, tooling design, and production troubleshooting.
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My work focuses on design for manufacturing, where ideas are shaped with real production constraints in mind—materials, tolerances, tooling limits, cost, and reliability. I have designed and reviewed hundreds of molds, dies, and production components used in plastic injection molding, high-pressure die casting, sheet metal forming, and aluminum extrusion.
I work comfortably at the intersection of design, production, and decision-making—supporting companies that need designs that actually survive the factory floor. My role is often to simplify complex designs, eliminate manufacturing risks early, and reduce iterations, cost, and time to market.
I collaborate remotely with global teams and offer flexible, part-time consulting for concept development, DFM reviews, tooling design, and production troubleshooting.
Experience
-
Technical Consultant
Machines & Aluminum Center · Full-time
Dec 2020 –
Present
5 yrs 2 mos
Giza Governorate, Egypt
As a Technical Consultant, I apply my Industrial Engineering expertise to guide the transition of new products from R&D into full-scale manufacturing systems. My role combines process optimization, design for manufacturability, and project management to ensure efficiency, quality, and continuous improvement.
Key contributions include:
• Conducting DFM evaluations and developing optimized manufacturing processes.
• Designing and validating molds, dies, and production tools with a focus on reliability and cost-effectiveness.
• Leading problem-solving initiatives using Lean Six Sigma and root cause analysis to resolve shop-floor challenges.
• Building and refining workflow systems and ERP integration to improve resource utilization and project tracking.
• Supporting R&D efforts by implementing innovative solutions that enhance tool performance, reduce downtime, and drive productivity.
This role allows me to bridge engineering design, process management, and system-level analysis, delivering impactful results across product and process development. -
Deputy General Manager
Pro Tec · Full-time
Apr 2017 –
Nov 2020
3 yrs 7 mos
Al-Sharqia Governorate, Egypt
In my role as Deputy General Manager, I combined business leadership with Industrial Engineering expertise to oversee operations, strengthen systems, and support company growth.
Key contributions:
• Quotations & Negotiations: Prepared cost analyses and quotations, ensuring competitive pricing while safeguarding profitability.
• Supplier & Customer Management: Built and maintained strong supplier relationships and engaged customers with clear technical and commercial proposals.
• Bills of Materials (BOMs): Developed accurate and detailed BOMs to streamline procurement and align production with material availability.
• Systems Optimization: Applied industrial engineering methods to monitor and optimize both financial and human resource systems, improving efficiency and cost-effectiveness.
• Process Management: Introduced structured workflows and reporting methods to improve coordination across departments.
This role strengthened my ability to bridge technical, managerial, and financial aspects of a manufacturing business — using engineering-based problem solving to support sustainable operations. -
R&D Manager
Pro Tec · Full-time
Jan 2006 –
Nov 2020
14 yrs 10 mos
Al-Sharqia Governorate, Egypt
As R&D Manager, I combined technical design expertise with industrial engineering methods to lead innovation in mold and die development and enhance manufacturing processes.
Key contributions:
• Design & DFM: Designed molds, dies, and production components tailored to customer requirements, while performing detailed Design for Manufacturability (DFM) evaluations to ensure efficiency and reliability.
• Process Innovation: Researched and developed new production techniques, integrating Lean and Six Sigma approaches to improve capability and reduce waste.
• BOM & Documentation: Created precise Bills of Materials (BOMs) and technical documentation, ensuring seamless coordination between design, procurement, and production.
• Problem Solving: Applied structured root cause analysis and industrial engineering tools to troubleshoot production challenges and optimize workflows.
• Continuous Improvement: Drove ongoing enhancements in manufacturing practices, aligning R&D activities with long-term business growth.
This role required a blend of engineering design, process optimization, and creative problem solving, allowing me to deliver high-quality solutions and scalable improvements in production systems. -
Production Manager
Pro Tec · Full-time
Nov 2004 –
Jan 2006
1 yrs 2 mos
Al-Sharqia Governorate, Egypt
In my first management role, I applied my Industrial Engineering background and hands-on technical expertise to lead daily production activities and optimize shop-floor operations.
Key contributions:
• Production Planning: Developed and managed production schedules to balance customer demand with available resources, improving on-time delivery and throughput.
• CNC & CAM Programming: Created CAM programs for CNC milling and wirecut machines, ensuring accuracy, repeatability, and efficiency in machining processes.
• Technical Documentation: Produced detailed technical drawings and process sheets, providing clear, standardized instructions for operators and technicians.
• Process Optimization: Applied industrial engineering methods (time & motion studies, workflow analysis) to streamline production and eliminate inefficiencies.
• Quality & Efficiency: Ensured production processes consistently met quality standards while minimizing downtime and material waste.
This role marked the foundation of my career — where I combined technical design, process analysis, and shop-floor management to strengthen the productivity and reliability of our manufacturing operations.
Education
- Cairo University Doctor of Philosophy (Ph.D.), Mechanical Design and Production Engineering 2011 – 2018
- Arab Academy for Science, Technology & Maritime Transport Master's degree, Industrial & Management Engineering, A 2005 – 2010
- Misr University for Science and Technology Bachelor's degree, Industrial and Systems Engineering, A+ with Honor 1999 – 2004
Other experience
- Consulting Engineering Design & Manufacturing
- Reverse Engineering and DFM Consulting (Informal)
- CAD Modeling Projects
- Molding Design
- Tooling and machining designer
- Design for Manufacturing (DFM)
- Mechanical Product Design
Stats
0 followers, 0 following
Age: 43
Joined: February 7, 2026
Last seen: February 7, 2026
Area of Expertise
3D Modeling
Mechanical Engineering
Injection Molding and Casting
2D to 3D Conversion Services
Reverse Engineering
Sheet Metal Design
Mold and Die Design Services
Mechanical 3D Rendering
Part-to-CAD Modeling
3D Models of Machine Parts
Assembly Drawing Services
Assembly Modeling Services
Mechanical Design Services
Metal Design and Fabrication
Mechanical CAD Design
3D Product Modeling
2D to 3D Modeling
Design for Manufacturing and Assembly
DFM Services
Design for Manufacturability (DFM Services)
Languages
Arabic Native or bilingual proficiency
English Professional working proficiency
Location
Cairo, Egypt