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Stefano M.

Mechanical product design engineer – DFM, injection molding, FEA (Fusion 360, CATIA)

São Paulo, Brazil

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Drones & UAV Design Ergonomics Injection Molding Mechanical Design SimScale

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About

I'm a mechanical product design engineer with 4+ years taking hardware from first concept to mass production. I don't just model parts — I design products that can actually be manufactured, assembled and sold.

WHAT I CAN DO FOR YOU
• Product design from sketch or requirements to production-ready CAD
• Plastic parts and enclosures designed for injection molding (DFM, draft, wall thickness, ribs, bosses)
• Electromechanical integration: fitting PCBs, batteries, sensors and cables into compact products
• Rapid prototypes for 3D printing (FDM, SLA, SLS) and CNC machining
• Structural optimization and FEA (Ansys, SimScale)
• Manufacturing drawings with GD&T, BOMs and supplier-ready documentation

SELECTED EXPERIENCE
• Binho (San Francisco hardware design firm, remote): mechanical design for 8 client electronics products — 2 launched, 1 in mass production. Built EVT prototypes, prepared a 10,000-unit injection-molded production run and worked directly with factories in China. Reduced product size by ~15% and manufacturing cost by 15–20%.
• Speedbird Aero: owned the mechanical design of the DLV-2 cargo delivery drone (UAV). Cut component weight by 40% (SLS) and 30% (CNC) and reduced wiring length by 20%.
• Brazilian Army (internship): CATIA modeling and ergonomic analysis of a military vehicle interior using digital human models.

TOOLS
Fusion 360, CATIA V5, Onshape, Ansys, SimScale, OpenBOM (PLM).

EDUCATION
B.Eng. in Automotive Engineering (5-year program, aerospace track) – University of Brasília. Technical Diploma in Mechanics. Published research on the ergonomic design of an all-terrain wheelchair.

HOW I WORK
Clear communication in English, regular progress updates and native files delivered (STEP, drawings, BOM). I ask the manufacturing questions early, so your design doesn't have to be redone when it reaches the factory. Based in Brazil (UTC-3), with good overlap with US working hours.

Experience

Senior Mechanical Engineer Binho Inc · Full-time Oct 2025 – Present 1 yrs 1 mos San Francisco, CA, USA Hardware product development firm that takes client electronics (wearables, robotics, IoT) from concept to mass production.

• Led mechanical design for 8 client products from concept to production: 2 launched, 1 in mass production, 3 in prototyping.
• Built 3 rapid-prototype iterations for EVT testing, refining designs for injection molding.
• Prepared injection-molded parts for a 10,000-unit first production run through DFM reviews and tooling feedback.
• Served as the direct mechanical contact for clients and factories in China on design, materials and DFM questions.
• Redesigned product architecture and component integration, reducing overall product size by ~15%.
• Reduced manufacturing cost by 15–20% through component selection and BOM optimization.

Tools: Fusion 360, SimScale.
Lead Mechanical & Systems Engineer Speedbird · Full-time Nov 2025 – Nov 2025 0 mos Franca, São Paulo, Brazil Brazilian developer of cargo delivery drones (UAV) for logistics and last-mile delivery.

• Owned the mechanical design and product development of the DLV-2 cargo drone, from concept to manufacturing and system integration.
• Designed components, assemblies and aircraft systems for CNC machining, composite manufacturing and additive manufacturing (SLS).
• Reduced SLS component weight by 40% and CNC-machined component weight by 30% through geometric optimization validated with Ansys FEA.
• Reduced wiring length by ~20% through improved component placement and system layout.
• Standardized part numbers and created reusable left/right components, reducing unique parts by ~15% and simplifying inventory and assembly.
• Applied GD&T to manufacturing drawings and managed product structure, BOMs and revisions in OpenBOM (PLM), integrated with the ERP.
• Managed engineering changes and nonconformances (ECRs/NCRs), coordinated with manufacturing suppliers and ran validation tests on systems and components.

Tools: Onshape, OpenBOM, Ansys.

Education

University of Brasília (UnB) Bachelor of Engineering, Automotive Engineering, MECHANIAL ENGINEERING 2016 – 2023 5-year engineering program with aerospace track. Capstone: conceptual design of an all-terrain wheelchair with ergonomic evaluation (published).
Federal Institute of Goiás (IFG) Technical Diploma in Mechanics, Mechanical 2012 – 2014

Other experience

Mechanical Design Consultant, Dona Bita, Goiânia, Mar – Nov 2022 • Designed commercial kitchen layouts in CATIA V5 and coordinated with equipment suppliers.
Engineering Intern, Brazilian Army, Brasília, Aug 2021 – Mar 2022 • Developed CATIA V5 3D models of the interior layout of the CCOp Mv military vehicle.
• Performed ergonomic analyses (RULA, Push/Pull, Biomechanics Single Action) using digital human modeling.
• Supported human-machine interaction studies through occupant questionnaires and interior mock-up evaluation.