Mechanical Design Engineer

Built to
perform.
Designed to
last.

Senior mechanical design engineer with 12+ years of experience across product design, high-volume manufacturing, and process optimisation — delivering precision-engineered solutions from concept to production.

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12+
Years experience
€200k
Annual savings delivered
HVM
Manufacturing specialist
DFM
Design for manufacture
What I offer

Three disciplines.
One engineer.

01 —
Consultancy & Advisory
Strategic engineering advice for businesses navigating complex mechanical challenges. With deep experience in ATEX, EU, UKCA, and ISO 9001 compliance, I help teams make informed decisions that save time, reduce risk, and cut costs.
Feasibility studies Root cause analysis Regulatory compliance Technical due diligence
02 —
Product Design & Development
End-to-end product design from initial concept through prototyping and validation. Specialist in precision machined parts, injection moulded components, polymer science, extrusions, sheet metal fabrication, and rapid prototyping.
SolidWorks / AutoCAD Rapid prototyping 3D printing Validation & testing
03 —
Design for High-Volume Manufacturing
Specialising in DFM and DFA for large-scale production. Experienced in designing fully automated pneumatic and electric assembly lines for international factories, applying lean methodologies and Design of Experiments (DOE) to drive down unit cost without sacrificing quality.
DFM / DFA Automation line design Tolerance analysis Lean & DOE
Background

Engineering at
every scale

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Galway-based mechanical design engineer with a BSc in Mechanical Engineering (First Class Honours) from the University of Nevada, Reno. I've worked across Ireland, England, and the United States — from early-stage startups to multinational manufacturers.

Notable collaborations
Barry Flannery — High Performance Battery Platforms
Andrew Ritchie — Brompton Bicycle
Martin-Baker — Aerospace Ejector Seats
SolidWorks / CAD
Expert-level design
DFM / DFA
High-volume specialist
Regulatory compliance
ATEX, EU, UKCA, ISO
Rapid prototyping
3D print & machining
Automation & assembly
Pneumatic & electric
Project leadership
Concept to production
Industries served
Battery technology Aerospace & defence Startup & scale-up Industrial automation Consumer products ATEX environments
How I work

A structured approach
to every engagement

01
Discovery
Understanding your challenge in full — technical requirements, commercial constraints, timelines, and what success looks like for your business.
→
02
Concept & strategy
Developing viable engineering approaches. Multiple concepts explored, evaluated, and shortlisted against your criteria before any commitment to a direction.
→
03
Design & validation
Detailed design work — SolidWorks modelling, tolerance analysis, DFM review, rapid prototyping, and iterative testing until the design is proven.
→
04
Delivery & handover
Full technical documentation, CE/UKCA compliance files, and engineering drawings handed over. Available for ongoing support through production ramp-up.
Let's talk

Ready to start
a project?

Whether you have a fully scoped brief or a rough idea that needs shaping, I'd like to hear about it. Reach out and we'll set up an initial conversation.

BasedGalway, Ireland — available remotely worldwide
Emailbtobey25@gmail.com
Phone085 158 0685
Websitetobeydesign.ie
AvailabilityCurrently accepting new engagements