A sample of the projects which I have successfully delivered.

1. 1
1
The drivetrain installed in the smart electric vehicle utilizes state of the art brushless DC motor technology
that is designed and manufactured in house by Zytek. Working closely with the client to integrate and
package there proprietary technology into the existing chassis, the innovative drivetrain design integrates
the electric motor, power and control electronics, into one compact assembly with only three connections:
water, High voltage(300V) and low voltage (12v).
The smart fortwo ev sets a new benchmark in the electric vehicle sector, the 55Kw drivetrain producing a
top speed of 120km/h. 12 kilowatt hours per 100 kilometres gives it a range of 110 kilometres. These figures
indicate that the smart fortwo ev is a vehicle that is ideal for short journeys in urban traffic.
It only takes three and a half hours to charge the battery from 30 to 80 percent of its capacity. An empty
battery can be fully charged in no more than eight hours, for example overnight.
Working from concept, through prototype build to ramp up for production, project deliverables included: 3D
Models, fully detailed drawings for manufacture, requiring extensive supplier liaison and development.
▲portfolio:
PROJECT1:ZYTEK AUTOMOTIVESMART FORTWO ELECTRIC DRIVETRAIN

2. 2
1
Sonic Communications (International) Ltd is a company who specialise in audio and
video communications technology and equipment. The project involved the redesign of
a Covert Personal Radio Unit.
From an ergonomic perspective it was critical that the user interface remained
consistent with other market products, due to operator familiarity with control layout
and functionality. A key area for improvement of the design was in tactile differentiation
between function keys, and the ability to reliably distinguish and operate the function
buttons/knobs through clothing.
The project required a close working relationship with the client company and end
user to meet a highly aggressive product introduction schedule, culminating in product
delivery within 6 months of taking the initial client briefing.
▲portfolio:
PROJECT2:SONIC COMMUNICATIONSRCU HANDHELD CONTROLLER

3. 3
1
The Patented design and development of a manual Quick Coupler for Mini-
Hydraulic excavators, allowing the quick interchange of front work tools.
Initial research involved looking at the other systems available on the market and
defining the strengths and weaknesses of each design in order to better understand
the market requirements and opportunities. Key weaknesses were defined as
being the loss in operational efficiency ranging from 15% to 20%, resulting from
the change to the linkage geometry, following the attachment of manual coupler
systems.
A virtual simulation of the linkage geometry was created which could be
manipulated and used to predict the effects of altering the pin locations in real time.
This resulted in a 5% improvement in efficiency over the current market leader.
Additional design considerations were the ergonomics of operation, packaging and
design for use in harsh and aggressive environments, which formed and important
part of the endurance programme for the product.
▲portfolio:
PROJECT3:CATERPILLAR UK LTDQUICK INTERCHANGE COUPLER

4. 4
1
The design and development of a front mounted stabilizer system for Telescopic Handlers. The brief
required a retro-fit-able optional attachment capable of providing up to 5 degrees of vehicle levelling, for
operation on uneven surfaces, with minimal impact on forward visibility, both during operation and when
stowed for roading. The client required a low risk, right first time design, due to the aggressive timescale
and high level of new engineering content involved in the other aspects of the programme.
The project was delivered from concept to fully detailed manufacturing prints within 5 weeks, with a design
meeting all the requirements of the initial brief.
Working from concept, through prototype build to ramp up for production, project deliverables included: 3D
Models, fully detailed drawings for manufacture and a technical report covering initial design calculations
and competitor analysis along with a detailed project plan to support the top level program milestones.
▲portfolio:
PROJECT4:CATERPILLAR UK LTDTELESCOPIC HANDLERFRONT STABILIZER SYSTEM

5. 5
1
The project involved design and development
of the key structural components for a 4-Section
Telescopic Handler, the largest machine in the
“B-Series” range and a first for the client with a
4-section boom and maximum lift height of 52ft.
A key design challenge was to provide the
structural rigidity to allow operators to utilise
the exceptional lift height for “Pick and Place”
operations. The use of a range of techniques
including Failure Modes & Effects Analysis
(FMEA) and Finite Element Analysis (FEA)
resulted in a design which went into production
without a single structural redesign, following extensive vehicle endurance and performance trials by the client.
Full responsibility was taken for the project management of the structural design, working from concept, through
prototype build, to ramp up for production, project deliverables included: 3D Models, fully detailed drawings for
manufacture (completed to the clients’ in house standards) along with a technical report supporting the design,
covering initial design calculations and preliminary FEA. Working within an ISO9001 quality environment.
▲portfolio:
PROJECT5:CATERIPLLAR UK LTDTH580 TELESCOPIC HANDLERCHASSIS+BOOMOUTER+STABILIZERS

6. 6
1
Forecourt Tyre Inflation gauges have remained unchanged for
a number of years and the products currently dominating the
market are considered unattractive, outdated and difficult to use.
The brief was to produce a new design for a Garage Forecourt
Tyre Inflation Gauge and Valve Connector, incorporating a digital
display, which was robust enough for the forecourt environment,
aesthetically appealing and intuitive to use.
The proposed solution used a Polypropylene (PP) based
elastomeric outer which was chemically bonded to the internal
Glass filled PP body shell. As well as offering a robust and
tactile protective shell the materials selection also meant the
product could be supplied in corporate colours for national
service stations. Other features of the design were an easy to
read display, intuitive operation and protection of the air hose
connection, which was recessed into gauge body.
The organic appearance was intended to move the product
styling away from the industrial aesthetic, making the device
appear less intimidating to users.
▲portfolio:
PROJECT6:FORECOURT TYRE INFLATION GAUGE

7. 7
1
The client was a small research and development company based in
Sydney, Australia. The project involved the design development, 3D
modelling and supplier management for the Passenger Compartment
of a prototype Electric People Carrier for the Sydney 2000 Olympic
Games.
Manufactured from Fibreglass using an epoxy polymer matrix and hand
lay-up techniques, the shell was firstly modelled in 3D, this model was
then used to derive spatial points for the construction of the prototype
mould. The project required a high degree of supplier management,
working with a team who had very little experience of moulding complex
geometry in fibreglass.
Working to an aggressive schedule the project was successfully taken
from 2D layout to working prototype within 4 months.
▲portfolio:
PROJECT7:ELECTRIC PEOPLE CARRIER