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Gustavo Alves D.

Senior Automotive Product Design & Checking Fixture Engineer | CATIA V5 | GD&T | Reverse Engineering

Porto Alegre, Brazil

Global rank:

18,115 / 144,814

Skill pts: 5

BIW Fixture Design Jigs and Fixture Design Manufacturing Processes Reverse Engineering

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About

I am a Mechanical Engineer with over 25 years of experience in the automotive industry, specializing in Product Design, Checking Fixtures, Inspection Fixtures, Master Blocks (Meisterbock), BIW tooling, GD&T, Reverse Engineering, and Dimensional Engineering.

Throughout my career, I have worked on the development, validation, and optimization of automotive components, welding fixtures, inspection fixtures, and manufacturing processes, supporting OEMs and Tier 1 suppliers in achieving high dimensional quality, improved manufacturability, and reduced production costs.

My expertise includes:

• CATIA V5 3D Modeling and Drafting
• Product Design (Plastic and Sheet Metal Parts)
• Checking Fixture & Inspection Fixture Design
• Master Block (Meisterbock) Design
• BIW Tooling and Assembly Fixtures
• GD&T (Geometric Dimensioning & Tolerancing)
• Tolerance Analysis and Dimensional Validation
• Reverse Engineering (Mesh to CAD)
• Manufacturing Feasibility (DFM/DFA)
• Problem Solving and Engineering Optimization

I have extensive experience collaborating with multidisciplinary engineering teams and supporting projects from concept through production, always focusing on quality, functionality, and practical engineering solutions.

If you are looking for an experienced engineering professional to support your product development, fixture design, reverse engineering, or dimensional engineering projects, I would be pleased to discuss how I can help.

Experience

Metrology engineer Toolmaker · Self-employed May 2023 – Present 3 yrs 3 mos Brazil Led the design and development of automotive products, checking fixtures, inspection fixtures, Meisterbock (Master Cubing) systems, and manufacturing tooling for OEMs and Tier 1 suppliers.

Responsible for product development of plastic, sheet metal, and BIW components using CATIA V5, ensuring compliance with customer specifications, GD&T requirements, manufacturing feasibility (DFM/DFA), assembly requirements, and dimensional quality throughout the product development process.

Performed dimensional engineering activities including tolerance analysis, fixture validation, reverse engineering, 3D scanning, CMM inspection, laser tracker measurements, PolyWorks analysis, virtual clamping, root cause analysis, and process optimization to solve complex dimensional and assembly issues.

Worked closely with multidisciplinary teams during product development, tooling validation, prototype builds, and production launch, supporting engineering changes, cost reduction initiatives, manufacturing improvements, and continuous quality enhancement.

Key expertise:
• Product Design (Plastic & Sheet Metal Components)
• CATIA V5
• Checking Fixture Design
• Inspection Fixture Design
• Meisterbock (Master Cubing)
• BIW Tooling
• GD&T
• Dimensional Engineering
• Reverse Engineering
• Tolerance Analysis
• Virtual Clamping
• Manufacturing Support
• Problem Solving
Project Leader | 3D Modeling & Laser Scanning AGP eglass · Full-time Jan 2023 – Present 3 yrs 7 mos Peru Project Leader responsible for the development of automotive glazing products, prototype manufacturing, and engineering tooling.

Led cross-functional engineering projects from concept to production, coordinating the design and validation of automotive glass components, checking fixtures, inspection fixtures, manufacturing tooling, gauges, and prototype equipment.

Managed the prototype development team, overseeing prototype builds, product validation, engineering changes, dimensional verification, and manufacturing readiness while ensuring compliance with customer specifications, quality standards, and project deadlines.

Worked extensively with CATIA V5 to develop plastic, sheet metal, and tooling components, supporting product development, assembly feasibility, GD&T implementation, dimensional engineering, and process optimization.

Collaborated closely with customers, suppliers, manufacturing, and quality teams to solve technical issues, reduce development time, improve product quality, and ensure successful product launches.

Education

Unisinos Bacharel engenharia mecânica, Mecahanical 2018 – 2025

Other experience

Automotive Designer (External Trim) Automotive Product Designer – Exterior Plastic Components

* Designed and developed exterior automotive plastic components from concept through production, ensuring compliance with customer requirements, cost targets, quality standards, and manufacturing feasibility.
* Created and modified 3D CAD models and 2D engineering drawings for injection-molded plastic parts, assemblies, and supporting components.
* Performed feasibility studies considering tooling, injection molding processes, assembly requirements, dimensional tolerances, and design optimization.
* Collaborated closely with cross-functional teams including Styling, Manufacturing Engineering, Tooling, Quality, Suppliers, and Vehicle Integration.
* Conducted design reviews, interference analysis, tolerance stack-up studies, and root cause investigations for dimensional and assembly issues.
* Applied GD&T principles to ensure functional requirements and dimensional compliance throughout the product development process.
* Supported prototype builds, validation activities, engineering changes (ECNs/ECRs), and product launches.
* Worked with suppliers during tooling development, mold tryouts, part validation, and production readiness.
* Optimized component design to improve manufacturability, reduce cost, weight, and cycle time while maintaining product performance and appearance.
* Developed solutions for assembly, fit & finish, sealing, fastening systems, clips, brackets, and interface with adjacent vehicle components.
* Supported dimensional validation using CMMs, 3D scanners, PolyWorks, and fixture inspections when required.
* Experienced in automotive exterior systems including bumpers, grilles, fascias, trims, spoilers, mirror components, and other injection-molded plastic parts.