Professional engineering design,
exactly when you need it

Independent Chartered Mechanical Engineer, delivering efficient design with momentum - from concept to prototype to product.

* I promise never to pass on your email or spam you.

Right-sized, collaborative development

Hello, I'm James. I work with founders, start-ups, scientists, and inventors. When a project calls for a focused development, proof-of-principle build, or prototype, you don't need a multi-year programme. I bring major-consultancy calibre design quickly and flexibly, so together we take the simplest path that fully meets the requirements.

I've built a strong network of technical, design, and manufacturing contacts. When we work together, that network becomes your leverage, helping us complete projects efficiently, with minimal investment, while still getting to the right answer.

I'm best when decisions are close to the work. If a project needs small teams, short loops, and clear ownership, I'm a good match.

Where this fits

  • Targeted, agile developments
  • Proof-of-principle & prototypes
  • Custom research test equipment
  • Lean budgets & tight deadlines

Probably not a fit

  • Large, highly integrated platforms with many teams and dependencies
  • Heavily regulated programs that need formal quality systems and extensive documentation
  • Projects that rely on long internal review cycles, steering boards, or heavy bureaucracy

Flexible Projects

Every project follows its own path. Instead of a rigid, one-size-fits-all process, I use a flexible framework of stages that can be added, removed, or reordered to fit the job. Small projects may only need one or two steps; larger ones may use the full set. By building and testing early, we address risk early, making it easier to adapt while changes are still simple and low-cost.

Explore project types

Modern CAD, zero software drama

Review your designs directly in your browser—no installs, no licences, just a link.

Review CAD in the browser

While I have several years of experience using Solidworks, Creo and Inventor, I prefer to use the latest cloud-based CAD software - Onshape, for the following reasons:

  • Share instantly: Review the live model in your browser - no installs.
  • Always current: Branches keep versions clear and conflict-free.
  • Everything together: Model, BOMs and datasheets in one version-controlled space.
  • Explore safely: Try options in parallel, then merge the best - no folder juggling.
  • Secure & resilient: Enterprise-grade security and continuous backups - work continues if a device fails.
  • Full history: Every change is tracked and reversible.
  • Software versions: Being cloud software, there are no version mismatch problems.
Onshape assembly: gripper
Review CAD in the browser

Experience

A quick overview of where I'm strongest — and where I'm still learning.

Core Mechanical Design
  • Mechanisms & Electromechanical Extensive experience designing diverse mechanisms and integrating electromechanical actuators.
  • Enclosures & Chassis Extensive experience designing enclosures and chassis across environments and manufacturing processes, with consideration for EMC, thermal management, cleanability, and fluid/particulate ingress and containment. Delivered safety-rated laser enclosures and interlocked access panels.
  • Optics & Kinematic Alignment Significant experience with the mechanical aspects of optical systems, including kinematic mounts and precision alignment features. I would involve an optical specialist for optical design and analysis, and I am comfortable implementing their specifications.
  • Sealing & IP Ratings Designed IP-rated enclosures and both pressurised-fluid and vacuum systems, often requiring stringent chemical compatibility and cleanliness.
  • Bearings Extensive experience selecting and integrating bearing types, with a solid understanding of fits, preload, lubrication, and service life/limitations.
  • Power transmission Experienced in selecting and integrating belts, pulleys, gears, lead screws, and chain drives, with a clear grasp of efficiency, backlash, and operating limits.
  • Fluid Power Systems Working knowledge of pneumatics and hydraulics. I would seek specialist input for complex circuit design and sizing, but I am comfortable implementing systems to a provided specification and designing the surrounding mechanics.
  • Microfluidics Working knowledge of microfluidics. I would seek specialist input for fluidic design, modelling, and surface chemistry, but I am experienced in implementing printed, embossed, machined, and moulded components to a specialist specification.
Designing for Manufacture
  • CNC Machining Extensive experience across 3-, 4-, and 5-axis milling/turning, tolerance stacks, surface finish, fixturing, and cost drivers. Strong local supplier network.
  • 3D Printing Experienced with FDM, SLA, SLS/MJF; design for orientation, supports, tolerances, and post-processing. Strong local supplier network. I run two FDM printers in house for very early prototyping and design exploration.
  • Laser, Waterjet Cutting & Photo-etching Regular use for prototypes and production, mindful of kerf/HAZ/taper, etc. Strong local suppliers.
  • Sheet Metal Extensive experience with bend design (K-factor, minimum flange, radii), hardware, weldments, and finishing. Proven local suppliers.
  • Thermoforming Comfortable designing parts and trim features with draw ratios, radii, and draft in mind. I collaborate closely with specialist suppliers on tooling and forming parameters.
  • Injection Moulding Good working knowledge. I have experience designing with draft, specific wall thickness, ribs, and control of sink/warp, and collaborate with toolmakers on gating/cooling, tolerances, and material selection.
  • Casting Some experience designing castable components with draft, wall thickness, ribs, and feature control in mind. I rely on supplier DFM feedback for finer details such as gating, cooling, and tolerance management, and engage toolmakers early in the process to guide the design. As with moulding, I would engage the supplier early in the process to guide the design.
Documentation
  • Technical Reports Strong experience writing concise, decision-oriented reports with clear, traceable assumptions and recommendations.
  • Rendering Capable of producing polished, marketing-ready visuals to support presentations, proposals, and design reviews.
  • Concept Sketching Competent at producing clear sketches to communicate ideas and mechanisms. Not a professional illustrator, but effective at rapid concept visualisation.
  • DFMEA Experienced in contributing to DFMEA as part of large, regulated programmes.
Analysis & Calculations
  • General Engineering Calcs Extensive experience performing and presenting a broad range of engineering calculations using Jupyter/Python. Comfortable with uncertainty quantification and sensitivity analysis to identify key parameters and validate assumptions.
  • Statics Confident with vectors, equilibrium, resultants, structures, internal forces, simple friction, inertia, etc. Lots of experience modelling complex static systems with Jupyter/Python to inform and validate designs.
  • Mechanics of Materials Confident with stress/strain, beams, torsion, buckling, bolted/interference joints, and fatigue basics. Apply appropriate safety factors and validate with calculation and test where needed.
  • Tolerance Stacks & GD&T Trained and experienced with datum strategy and GD&T (ASME Y14.5 and ISO GPS). Experience performing and visualising worst-case/RSS stacks and Monte Carlo assembly simulations in Python.
  • Dynamics Working knowledge of kinematics and kinetics. Practical experience of vibrations and resonance in mechanisms. I can research more complex topics to develop calculations as needed.
  • Fluid Dynamics Good understanding of basic fluid principles, but am less confident with advanced topics. I would seek specialist input for complex fluid systems, but I'm always willing to research and learn where required.
  • Thermodynamics I have some experience with basic heat transfer calculations and estimates, but would seek specialist input for more complex thermal systems. I'm always willing to research and learn where required.
Electronics
  • Systems Integration Experienced in specifying and integrating motors, drives, sensors, and controllers. Comfortable with tidy cable routing, grounding, and basic EMC considerations.
  • PCB Integration Confident in integrating PCBs into mechanical assemblies, interpreting ECAD data, and ensuring accessibility, thermal management, and serviceability.
  • Safety Systems Experienced in integrating interlocks, light curtains, and e-stops into mechanical systems. I would involve an electrical engineer to design and sign off circuits.
  • High-Voltage Systems Broad experience implementing high-voltage designs and enclosures which have been specified by an electrical engineer. Final review and sign-off by a qualified electrical engineer.
  • RF Systems Some experience integrating RF modules and antennas mechanically, with awareness of shielding and placement effects. I'd require RF specialists for layout and compliance.
  • Debugging Electronic Systems Basic capability for probing signals and logging with an oscilloscope. I engage electrical engineers for deeper fault-finding and circuit-level troubleshooting.
  • Custom PCB Design Not a capability I offer directly. I engage electronics engineers for all board design and support them with mechanical integration requirements.
Software
  • Onshape Very confident with Onshape's cloud-native workflows, collaboration tools, and unique feature set.
  • SolidWorks Extensive experience with complex assemblies, detailed drawings, and surfacing. Comfortable rescuing and repairing legacy models.
  • PTC Creo Competent with parametric workflows and managing large assemblies. Would refresh knowledge as needed on a new project.
  • Autodesk Inventor Significant experience a few years ago. Would refresh knowledge as needed on a new project.
  • Keyshot Confident producing photorealistic renderings. I would defer to a specialist for complex scenes or animations.
  • Python Strong capability in automation, data handling, and testing. Comfortable using Jupyter notebooks for transparent, version-controlled calculations. Confident building cleanly architected larger applications.
  • C# Hands-on experience a few years back. Could pick it up again quickly if required, though not a current core skill.
0–30%: learning 40–70%: competent 80–100%: experienced

About me

I'm a Chartered Mechanical Engineer with first-class master's degrees in Mechanical Engineering and Intelligent Systems & Robotics, and over 15 years' experience developing products and machines in professional settings.

I am experienced in designing electro-mechanical systems in a wide range of contexts, including life science, renewable energy, scientific equipment, packaging equipment, and heavy industry.

I have had the opportunity to work end-to-end across the development processes, seeing several products progress from initial sketches and into final production. I have been the sole design engineer on several major programmes during my time in industry.

Previous Career snapshots

TTP Electro-mechanical systems for life science

Mechanical engineering consultant delivering electromechanical solutions for life-science instruments. I worked hands-on across optics, thermal control, pneumatics, and microfluidics, from CAD and analysis to prototype build and test. Tools included Onshape, Creo, SolidWorks, and Python for modelling and control.

Blacktrace Scientific and laboratory equipment

Mechanical design engineer turning biotech and flow-chemistry concepts into production hardware. Full product development lifecycle: concept to CAD in PTC Creo with Windchill, electronics integration, and test builds. Wrote C# and Python tools, ran DFMEAs, and built jigs to speed production and improve quality.

AXISCADES CAE/FEA

UK CAE project manager delivering FEA and analytical models for design validation and specification. I produced technical reports, advised clients, and led remote teams in India to deliver safety-critical mechanical analyses. Tools: PTC Creo/Simulate, Inventor, MATLAB, Altair HyperWorks.

Intelligent Energy Fuel-cell modules

Mechanical design engineer on evaporatively cooled hydrogen fuel-cell systems. Designed low-voltage modules and cell stacks, ran FEA, and took concepts to lab rigs and prototype tests. SolidWorks with PDM; statistical analysis to drive design decisions.

Terex Quarry equipment

Design engineer on the Terex jaw-crusher team in Coalville. Built heavy machinery in Creo and Simulate with Pulse PDM, designing for machining, casting, and fabrication, and running quarry trials. Progressed into crushing-chamber FEA, fatigue assessment, and a Python wear model; designed and validated lifting accessories to BS EN 13001; represented Terex in the National Engineering Education Scheme.

Approach

  • Do less, do it better.
  • Keep it simple.
  • Prototype early, fail fast, learn quickly.

Qualifications and Training

  • PhD, Computer Science (in progress)
  • MSc, Intelligent Systems & Robotics (1st)
  • MEng, Mechanical Engineering (1st)
  • GD&T Training
In the past, I have worked on:
  • Medical diagnostic equipment
  • Carbon capture systems
  • Packaging machines
  • Industrial freezer systems
  • Rock crushing equipment
  • Laboratory automation equipment
  • Cell therapy systems
  • Fuel storage tanks
  • PCR Machines
  • Printers
  • Dakar race vehicles
  • Microscopes
  • Cell sorting machines
  • Telehandlers
  • Hydrogen fuel cell systems
  • Medical consumables

Let's connect

Whether you want to explore ideas, discuss a project, or just chat through possibilities, I'm always open to a conversation.

* I promise never to pass on your email or spam you.

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