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Erol A.

Lead Industrial Designer & Reverse Engineering Expert | SolidWorks & Geomagic

Istanbul, Turkey

Global rank:

4,919 / 133,018

Skill pts: 10

Geomagic Design X Geomagic Qualify 8 Mechanical Engineer Mechanical Engineering Rhinoceros (RhinoCAD, Rhino 3D 8

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About

Welcome to my profile. I am Erol Alkaya, the Founder and Lead Industrial Designer of Helix Design Studio. With extensive experience in mechanical engineering and product development, I bridge the critical gap between conceptual ideas and the actual production floor.

I don't just draw 3D shapes; I engineer functional, production-ready parametric solids. Whether you are an inventor looking to prototype a new consumer product, or a manufacturer needing high-precision reverse engineering from 3D scan data, I provide solutions built on strict Design for Manufacturing (DFM) principles. I approach every project with a toolmaker's perspective.

My Core Expertise Includes:

High-Precision Reverse Engineering (Scan-to-CAD): Expert-level workflow using Geomagic Design X and SolidWorks to convert dense STL/OBJ scan data into clean, fully editable parametric models. I provide 3D deviation analysis (heat maps) to guarantee dimensional accuracy.

Plastic Injection Molding & DFM: Deep knowledge of tooling requirements, including draft angles, uniform wall thickness, sink mark prevention, undercut resolution, and mechanical assembly features (snap-fits, screw bosses).

3D Printing & Prototyping Optimization: Engineering complex, multi-part assemblies, interlocking joints, and smart sectioning for FDM, SLA, and SLS additive manufacturing.

Professional Deliverables: Supplying native, feature-based SolidWorks assemblies, watertight neutral formats (STEP, IGES), and comprehensive 2D technical production drawings.

When you collaborate with Helix Design Studio, you are partnering with an engineer who ensures your product is designed to fit, function, and manufacture flawlessly without costly downstream errors.

Let’s discuss your project and bring your engineering data to life.

Portfolio

Experience

Founder Helix Tasarım · Full-time Apr 2015 – Present 11 yrs 1 mos Istanbul, İstanbul, Türkiye Helix Design Studio was founded to solve a critical problem in the product development industry: Creating designs that don't just look good on a screen, but manufacture flawlessly on the production floor.

The success of an industrial product lies in its manufacturability. At Helix Design Studio, we don't approach projects simply as draftspersons; we look at them through the lens of a toolmaker, machinist, and mechanical engineer. Founded by Lead Industrial Designer Erol Alkaya, the studio’s DNA is built on extensive field experience in plastic injection molding, tooling architecture, and reverse engineering. To us, a CAD file isn't just a 3D model—it is a precise manufacturing roadmap engineered with exact wall thicknesses, draft angles, material shrinkage rates, and assembly tolerances.
Reverse Engineering & Precision Tooling Specialist Eren Automotiv · Full-time Jun 2015 – Mar 2026 10 yrs 9 mos Istanbul, İstanbul, Türkiye At Eren Otomotiv, I focused on classic cars and contributed to the redesign and production processes of parts that were not available. I specialised in product design, prototype development and preparation for mass production. I offered solutions that combine functionality with modern production techniques while preserving the original character of classic vehicles.
Reverse Engineering & Precision Tooling Specialist Beşduyu Tasarım · Full-time Feb 2013 – May 2015 2 yrs 3 mos Istanbul, İstanbul, Türkiye At Beşduyu Tasarım, I served different sectors in the fields of product design and reverse engineering. By taking part in projects for the automotive, kitchen, bathroom and toy sectors, I brought my designs together with functionality and aesthetics. I contributed to the production processes in the CNC vertical machining machine added to the company. In addition, I gained experience in prototype development and production stages by taking an active role in the transformation processes of the products designed with 3D printers added later.

Education

Anadolu University Industrial + Product Design, Industrial / Product Design 2008 – 2012

Other experience

DFM for High-Volume Injection Molding: Extensive background in auditing product concepts specifically for injection molding failure points before tooling begins, acting as a bridge between the industrial design team and the steel mold fabricators.
Medical Orthotics & Custom Additive Manufacturing: Specialized expertise in applying 3D scanning and reverse engineering workflows specifically for the 3D-printed medical orthotics sector, adhering to the high precision and ergonomic standards required in the European market.
Production Costing & Material Estimation: Beyond CAD modeling, I have practical experience in calculating complex production costs, material requirements, and labor operations (such as polishing and finishing) for medium-volume manufacturing runs (e.g., aluminum component sets). I factor in everything down to metal scrap value, ensuring my designs are not just functional, but economically optimized for the production floor.