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Ahmed A.

Senior Mechanical Design & R&D Engineer | SolidWorks Expert & Siemens NX | FEA · DFM/DFA · Reverse

Cairo, Egypt

Global rank:

14,508 / 136,727

Skill pts: 5

Autodesk Inventor CAD Design Mastercam Reverse Engineering Transmission Design

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About

Senior R&D Mechanical Design Engineer with 6+ years of end-to-end experience developing complex industrial systems, robotic automation, and precision machinery. Certified SolidWorks Expert and professional trainer, with deep hands-on expertise in Siemens NX, ANSYS (FEA/CFD), and Autodesk Inventor.
My core strengths span the full design lifecycle — from concept and 3D modeling to structural simulation, DFM/DFA optimization, and production-ready documentation. I specialize in precision transmission design using KISSsoft and GearTech, and manage design data through SolidWorks PDM/Vault and Autodesk Vault.
I hold a rare combination of skills: advanced Reverse Engineering using Geomagic Design X (Scan-to-CAD from point clouds and STL data), 5-axis CNC programming with Mastercam and NX CAM, and applied AI research in Robot Vision and Deep Learning (Python/PyTorch/CNN) for industrial environments.
Notable experience includes leading R&D of 5-axis painting robots and palletizer systems at EMATECH, CNC programming for optical components on DMG/Mazak/Haas machines at Arab International Optronics, and full product lifecycle management via Odoo ERP across multiple industrial sectors.
B.Sc. Design & Production Engineering — Mansoura University (Highest Honors, 1st of Class). IELTS Academic 7.5. Certifications: SolidWorks Expert, Sandvik Metal Cutting Technology, Quality Control (AUC), TOT (Supreme Council of Universities).

Experience

Mechanical Design & Reverse Engineering Engineer CGN Center (Auto Lab) · Freelance Jan 2026 – Present 5 mos Egypt • Scan-to-CAD Processing: Expertise in processing 3D scanning data (STL / point clouds) using
Geomagic Design X to generate accurate, manufacturable CAD models.
• High-Fidelity Modeling: Developing high-quality SolidWorks surface and solid models from
3D scan data, ensuring strict dimensional accuracy and design intent.
• Production Optimization: Applying Design for Manufacturing (DFM) principles to convert
scanned and reverse-engineered models into production-ready designs.
Technical Skills: Geomagic Design X, SolidWorks (Surface Modeling), 3D Scanning, Scan-to-CAD
(STL/Point Clouds), Reverse Engineering, DFM
R&D Mechanical Design Engineer EMATECH For Engineering Solutions · Full-time May 2025 – Present 1 yrs 1 mos Egypt • Robotics & Automation Design: Led R&D and system integration for complex 5-axis and
palletizer robots using SolidWorks/ SOLIDWORKS PDM / Autodesk Inventor/Autodesk Vault,
reducing design-to-prototype cycle time by [30] %.
• Transmission & Kinematic Engineering: Engineered high-performance rotating assemblies and
developed mathematical models (KISSsoft, MATLAB), extending bearing lifecycles by [10] %.
• FEA & Structural Optimization: Conducted advanced stress, fatigue, and vibration FEA (ANSYS),
successfully reducing robotic arm weight by [9]% without compromising payload capacity.
• Lifecycle & Quality Management: Managed design iterations and BOMs via SolidWorks PDM, applying
strict DFM/DFA principles and ASME Y14.5 GD&T standards to reduce assembly time by [5] %.
• Technical Skills: SolidWorks, Inventor, Vault, ANSYS (FEA/CFD), CATIA V5, KISSsoft, MATLAB,
Mathcad, DFM/DFA, GD&T (ASME Y14.5), SolidWorks PDM, Precision Transmission, Tolerance
Stack-up.
Faculty of Engineering Faculty of Engineering · Full-time Jan 2021 – Present 5 yrs 5 mos Egypt • Technical Instruction & Training: Delivered academic coursework and TOT-certified training
in SolidWorks, Mastercam (5-Axis), NX CAM, and GD&T (ASME Y14.5) to over [90] % engineers
and students.
• CNC Lab Management: Directed the Advanced Machining Lab, optimizing 4/5-axis
milling/turning workflows and G-code programming to increase hands-on manufacturing
competency by [10]%.
• Simulation & Metrology: Led practical workshops in ANSYS (FEA) and managed the Mechanical
Testing Lab, executing standardized impact and wear tests to validate material integrity.
• Curriculum & Research: Developed comprehensive curricula for complex assemblies and
surface modeling, designing experimental setups to support advanced manufacturing R&D
projects.
Technical Skills: SolidWorks, Mastercam (5-Axis), NX CAM, ANSYS (FEA), GD&T, CNC
Programming, Metrology, Material Testing, Technical Training, Academic Research, Curriculum
Development, Mentorship
R&D Mechanical Design Engineer ONE STACK For Industrial Supplies · Full-time Sep 2023 – May 2025 1 yrs 8 mos Egypt End-to-End R&D & Reverse Engineering: Led the full product lifecycle and reverse engineering of
complex systems using SolidWorks, Fusion 360 and Siemens NX, accelerating time-to-market by [30]%.
• DFM/DFA & Manufacturing Optimization: Optimized components for Sheet Metal, CNC
Milling/Turning, and Wire EDM, applying rigorous DFM/DFA to reduce production lead times by [25]%.
• FEA & Prototyping: Conducted stress and fatigue FEA (ANSYS) under operational loads, and
provided on-site troubleshooting to decrease prototype iteration failures by [60]%.
• ERP & Lifecycle Management: Managed multi-level BOMs, ECNs, and cost estimations within
Odoo ERP and ATR Custom Tools, while generating high-fidelity manuals in SolidWorks
Composer to improve assembly workflow efficiency by [50]%.
Technical Skills: SolidWorks, Siemens NX, Inventor, Fusion 360, SolidWorks Composer, ATR
Custom Tools, Odoo ERP, ANSYS (FEA), GD&T (ASME Y14.5), DFM/DFA, Reverse Engineering,
Sheet Metal, BOM Management.
Sheet Metal & Workshop Engineer Syamco Company for Contracting & Metal Working · Full-time Dec 2022 – Sep 2023 9 mos Egypt • Sheet Metal Design: Engineered complex parts in SolidWorks/Fusion 360, using K-factor
calculations for precise flat patterns to cut design rework by [95]%.
• CNC & Nesting Optimization: Programmed DXF files for laser and punching operations,
utilizing advanced nesting to reduce scrap waste by [5]%.
• Production & Drafting: Managed stamping/forming workflows and delivered accurate
DraftSight/AutoCAD shop drawings, accelerating workshop production time by [20]%.
• Reverse Engineering: Reverse-engineered legacy metal parts and optimized shop-floor
workflows, increasing overall manufacturing efficiency by [80]%.
Technical Skills: SolidWorks (Sheet Metal), Fusion 360, DraftSight, AutoCAD, DXF Nesting, KFactor & Bend Calculations, Stamping & Forming, Reverse Engineering.
Manufacturing Engineer & CNC Programmer Arab International Optronics (AIO) · Full-time May 2020 – Jan 2021 8 mos Egypt • Multi-Axis Programming: Developed and optimized complex 4-axis milling programs for
DMG, Mazak, and Haas machines using advanced CAM software, focusing on high-precision
optical and mechanical components.
• G-Code Optimization: Refined G-code and Fanuc macro programming to reduce cycle times and
improve surface finish quality through strategic cutting tool selection and speed/feed optimization.
• Fixture Design: Engineered custom work-holding fixtures to ensure part stability and
repeatability, reducing setup times by [5]% through detailed Job Setup Documentation.
• Production Support: Provided on-machine troubleshooting and technical support to operators,
ensuring zero-defect production and maintaining high-accuracy tolerances.
Technical Skills: Mastercam, NX CAM, Inventor CAM, Fusion 360, G-Code/M-Code
(Fanuc/Mazak/Haas), 4/5-Axis Machining, Fixture Design, SolidWorks.
Machine Tools Design Engineer CNC Leaders Cutting Tools · Full-time Jul 2019 – May 2020 10 mos Egypt • Machine & Transmission Design: Designed 5-axis grinding machinery and precision power
transmission systems, utilizing KISSsoft and MITCalc to optimize gear geometry, shaft
alignment, and bearing lifecycles.
• FEA & Precision Tolerancing: Executed structural and vibration FEA (ANSYS) and applied strict
GD&T (ASME Y14.5) with tolerance stack-up analysis, successfully achieving micron-level
manufacturing precision.
• Reverse Engineering & Documentation: Reverse-engineered obsolete components and
generated comprehensive fabrication drawings, routing sheets, and multi-level BOMs to
minimize production lead times by [15]%.
• Global Sourcing & Reliability Upgrades: Managed international technical procurement (RFQs,
cross-border sourcing) and collaborated with maintenance teams to implement design flaws
corrections, improving machine reliability by [30]%.
Technical Skills: SolidWorks, Inventor, CATIA V5, AutoCAD, ANSYS (FEA), GearTech, KISSsoft,
MITCalc, GD&T, Tolerance Analysis, Reverse Engineering, BOM Management, Technical
Procurement

Education

Mansoura University Bachelor’s in Design and Production Engineering, Design and Production Engineering, 3.9 2014 – 2019

Other experience

Technical Instruction & Training Delivered academic coursework and TOT-certified training
in SolidWorks, Mastercam (5-Axis), NX CAM, and GD&T (ASME Y14.5) to over [90] % engineers
and students.

Licenses & Certifications

IELTS (Academic) British Council Apr 2025 – Present
Training of Trainers (TOT) Supreme council of universities Aug 2024 – Present
SOLIDWORK Expert & professional Dassault systems Jan 2022 – Present
DIPLOMA OF Metal Cutting Technology Sandvik Coromant Academy Jan 2022 – Present
Certification in quality control principles and practices. THE AMERICAN UNIVERSITY IN CAIRO Jul 2019 – Present