Elhammiri Reda
Mechanical Design Engineer | CATIA V5 & SolidWorks
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This project showcases the complete design and engineering development of a high-performance automotive disc brake system inspired by the architecture and engineering standards used by Brembo. The entire system was researched, designed, and modeled by rom scratch, following real mechanical design principles and manufacturability constraints. The project includes the modeling of a ventilated brake disc, hub interface, and integrated braking components assembled with realistic mechanical logic. Detailed engineering drawings with GD&T according to ISO standards were also developed. The full design and assembly were created using SolidWorks, demonstrating my skills in mechanical design, CAD modeling, and technical documentation.đź§
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Differential Mechanism – Kinematic Motion Simulation
This part of the project focuses on the kinematic motion simulation of the differential mechanism created in SolidWorks. A motion study was performed to demonstrate how the gears rotate and distribute torque between two output shafts. The simulation illustrates the functional behavior of the differential when the wheels rotate at different speeds, highlighting the dynamic interaction between the spider gears and side gears.
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High-Performance Exhaust Collector Design – Audi RS6
This project focuses on the 3D modeling of a high-performance exhaust collector inspired by an AkrapoviÄŤ system for the Audi RS6. Using SolidWorks, the collector geometry was recreated from reference images. The design emphasizes smooth merging transitions between pipes to improve exhaust flow and maintain balanced gas distribution. Special attention was given to curvature continuity and realistic mechanical proportions to reflect a performance-oriented exhaust component.
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Automotive Emblem & Logo Pull-Off Test System
Designed and engineered a pull-off testing system to validate adhesion strength and mechanical resistance of automotive emblems and logos. Conducted research and development to define the most accurate force application and measurement solution. Performed FEM analysis and precise mechanical dimensioning to ensure structural stability. Delivered full 3D modeling and detailed 2D drawings for all parts and the complete system to support manufacturing and validation requirements.
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3D design and structural modeling of a hydraulic press frame
This project presents the 3D modeling and structural design of a hydraulic press frame developed using SolidWorks. Inspired by a reference image of an industrial hydraulic press, the design was recreated and engineered into a detailed CAD model. The project focuses on the main structural components, including the base frame, vertical supports, and upper beam, ensuring rigidity and stability under high compressive loads. Special attention was given to alignment, structural strength, and design for manufacturability, resulting in a robust and realistic mechanical structure suitable for industrial press applications.
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Porsche Front Axle & Suspension System
This project presents the complete reverse engineering and 3D reconstruction of a Porsche front axle support system, entirely designed and modeled by me from visual references and technical research. The objective was to transform real-world images into a coherent and mechanically functional engineering system, demonstrating strong mechanical reasoning, spatial analysis, and the ability to recreate complex automotive assemblies from scratch.
The system includes the modeling of the front axle support structure, a double-joint strut suspension architecture, control arms, damping components, and an integrated braking assembly. All components were designed with realistic geometry, assembly logic, and mechanical constraints using CATIA V5
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Audi Rear Differential Reverse Engineering & 3D CAD Mechanical System
This project consists of the complete 3D reconstruction of an Audi R8 rear differential system based solely on reference images. The objective was to demonstrate strong mechanical visualization skills and the ability to transform photos into a fully functional and technically coherent mechanical assembly while respecting engineering standards.
🔹 Reverse-engineered the full gear architecture (bevel gears, housing, shafts, bearings)
🔹 Recreated realistic assembly logic and mechanical interfaces
🔹 Applied proper tolerancing logic and mechanical dimensioning principles
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This project showcases the complete 3D design of a high-performance off-road buggy developed in SolidWorks. The model includes a fully tubular space frame chassis engineered for maximum rigidity and lightweight performance. The suspension system was designed with double wishbone geometry and long-travel coilover dampers to ensure optimal stability, wheel articulation, and shock absorption in extreme off-road conditions.
The design integrates steering mechanisms, mounting brackets, wheel hubs, and structural reinforcements while maintaining proper load paths and weight distribution.
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This project demonstrates my ability to transform visual references into a complete 3D mechanical design using advanced surfacing techniques. Based on images and conceptual inspiration, I recreated the geometry by analyzing proportions, curvature flow, and structural logic to build a coherent and realistic model. The design process required strong spatial interpretation, engineering judgment, and surface continuity control to achieve a smooth and functional form. The entire model was developed using the surfacing capabilities of SolidWorks, showcasing my skills in complex 3D modeling, surface reconstruction, and the translation of visual concepts into manufacturable engineering geometry.
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Sunroof Fatigue & Durability Test Bench
My role. Desig Opening/Closing Mechanism Validation
Developed a fatigue test bench to validate the durability of automotive sunroof opening and closing mechanisms. Led R&D activities to define the optimal mechanical architecture and testing methodology. Performed FEM analyses and mechanical dimensioning to ensure system robustness under cyclic loading. Designed the complete system in 3D and produced detailed 2D manufacturing drawings for all components and assemblies to guarantee reliability and long-term validation performance.
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Performance Exhaust Pipe Routing Design
Description
This project presents the 3D design of the exhaust pipe routing inspired by an AkrapoviÄŤ system for the Audi RS6. Developed in CATIA V5, the pipes were modeled to reproduce smooth curvature and realistic routing similar to a high-performance exhaust layout. The design focuses on continuous pipe geometry, balanced bends, and accurate proportions to reflect the structure of a performance exhaust pipeline.
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Mechanical Design Engineer | BIW & Stamping
I specialize in Body-in-White (BIW) design and sheet metal forming (stamping) using Catia V5. My expertise covers designing complex BIW structures, selecting optimal sheet thicknesses, defining draft angles for stamping, applying precise bend radii, and creating ribs and reinforcements to enhance rigidity while minimizing weight. I ensure dimensional tolerances, assembly feasibility, and crash safety compliance. I have hands-on experience designing inner door panels and other BIW components, delivering manufacturable, high-performance solutions for automotive projects.
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Mechanical Design Engineer | Plastic Parts & Injection Molding
I specialize in plastic part design for automotive applications using Catia V5. My expertise includes defining wall thicknesses, draft angles, and fillets to ensure manufacturability and structural integrity. I design ribs and reinforcements to optimize stiffness without adding weight, and apply precise tolerances for assembly and functional performance. Experienced in injection molding principles, material selection, and surface finishes, I deliver durable, lightweight, and aesthetically refined plastic components for complex automotive systems.
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I specialize in the design and engineering of sheet metal stamping parts (emboutissage) for automotive and industrial applications. My work focuses on creating manufacturable components that respect forming constraints, structural requirements, and industry standards. I design parts with optimized sheet thickness, appropriate draft angles for stamping, correct bend radii, and reinforced geometries such as ribs and flanges to ensure strength and weight efficiency. I also apply proper tolerancing strategies and assembly considerations to guarantee manufacturing feasibility. My designs are developed using professional CAD tools such as CATIA V5, ensuring compliance with real-world manufacturing and engineering standards.
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Plastic chair using advanced 3D CAD
I designed a high-quality plastic chair using advanced 3D CAD techniques, focusing on Class-A surfaces to ensure smooth, visually flawless aesthetics and ergonomic comfort. Each surface was carefully curve-verified to maintain perfect continuity and tangency, ensuring the chair’s design flows naturally while remaining manufacturable.
Using Zebra analysis, I evaluated surface reflections to detect and correct any bumps, ripples, or imperfections, achieving a visually premium finish. The final design not only meets ergonomic and aesthetic standards but is also fully optimized for injection molding production, combining engineering precision with elegant, manufacturable plastic design.
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Computer Mouse Design with Class-A Surfacing and Zebra Analysis
I designed a high-quality computer mouse with a focus on Class-A surfaces to ensure smooth, visually flawless aesthetics and ergonomic comfort for prolonged use. Using curve verification techniques, I carefully controlled surface continuity and tangency to achieve a flowing, elegant design that is both visually appealing and manufacturable.
Zebra analysis was employed to evaluate surface reflections, detect any irregularities, and refine the model for a premium finish. The final design is fully optimized for injection molding production, combining ergonomic functionality with engineering precision and high-end visual quality.
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Sheet Metal Engineering Design
Design and development of precision sheet metal components following international industrial standards. The project focuses on manufacturability, structural integrity, cost efficiency, and compliance with production constraints.
All parts were modeled and detailed using professional CAD tools, ensuring compatibility with real manufacturing processes such as laser cutting, bending, punching, and welding.
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81
Design Steering Articulation FEA & Lightweight Structural Optimization
This project consists of a complete Finite Element Analysis (FEA) and structural optimization of an automotive steering joint.
The objective was to validate mechanical resistance, improve structural rigidity, reduce weight, and optimize manufacturing cost while ensuring safety compliance.
🔹 Applied structural FEM principles
🔹 Selected appropriate mesh type for accurate simulation
🔹 Performed mesh refinement in critical stress zones
🔹 Conducted convergence verification
🔹 Calculated and validated safety factor
🔹 Optimized geometry to increase stiffness
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Automotive Shower Test Bench (Water Tightness Validation)
Designed and developed an automotive shower test bench to validate vehicle sealing performance under extreme rainfall conditions (1800 mm/h) with multiple slope configurations. Conducted R&D to define the technical concept, performed FEM analyses to ensure structural integrity, and completed full mechanical dimensioning. Produced detailed 2D drawings for every component and the complete system assembly. The solution ensured repeatable, reliable water ingress validation before industrialization.
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Mechanical Design Engineer | GD&T & 2D Technical Drawings Expert
I provide precise 2D technical drawings and GD&T services, ensuring designs are fully manufacturable and compliant with ISO and ASME Y14.5 standards. I define tolerances and dimensions based on part function, material type, and manufacturing process. My work ensures proper fit, form, and function within assemblies, while optimizing quality, cost, and manufacturability. Experienced with complex mechanical systems, I create drawings that clearly communicate functional requirements, assembly constraints, and critical features for production and inspection. Using CATIA V5 & SolidWorks
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Mechanical Design Engineer | GD&T & 2D Technical Drawings Expert
Project description.
I provide precise 2D technical drawings and GD&T services, ensuring designs are fully manufacturable and compliant with ISO and ASME Y14.5 standards. I define tolerances and dimensions based on part function, material type, and manufacturing process. My work ensures proper fit, form, and function within assemblies, while optimizing quality, cost, and manufacturability. Experienced with complex mechanical systems, I create drawings that clearly communicate functional requirements, assembly constraints, and critical features for production and inspection. Using CATIA V5 & SolidWorks
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