Portfolio

A selection of projects from over 15 years in mechanical design, manufacturing and project delivery. Client and employer details are kept confidential.

1. Value Engineering — Steel Consumer Product Range

Challenge: Reduce the cost of a range of welded steel products without compromising strength or user experience.

Approach: Material optimisation, simplified weldments and reduced part count, validated with FEA and physical load testing.

Result: Up to 30% cost reduction in key components and 20% faster assembly.

2. Multifunctional Tool — Aircraft Landing Gear Maintenance

Challenge: Four separate tools were needed for one maintenance process, which slowed production.

Approach: Concept design and adaptation of the four tools into a single multifunctional tool, with SolidWorks design and simulation.

Result: 50% reduction in production time. The tool was approved by the landing gear OEM and sold worldwide.

3. HVAC Installation — FIFA World Cup 2014 Stadium

Challenge: Install a large-scale HVAC system at one of Brazil's largest stadiums under a fixed tournament deadline.

Approach: Led on-site installation, coordinating three teams of 10+ people plus subcontractors, and supported the tender evaluation for equipment selection.

Result: System delivered for the 2014 World Cup.

4. Custom Heat Exchangers & Manufacturing Layout

Challenge: Deliver a high volume of custom radiators and heat exchangers to client specifications on tight lead times.

Approach: Design and calculation of units to spec, plus a redesign of the manufacturing layout, tooling and storage.

Result: Faster assembly flow, lower manufacturing time and cost, and a safer workshop.

Have a similar challenge? Email filipe@fsengineeringsolutions.com or call 0452 532 610.