R&D Mechanical Design Engineer
R&D-driven mechanical design engineer specialized in biomechanics for gym equipment — engineering complex mechanisms, then preparing the manufacturing files and patent drawings that turn ambitious ideas into certified, production-ready machines.
Showreel · 4 services
One short film for each service I offer, with the deliverables you actually receive.
Commercial gym machines engineered in SOLIDWORKS and checked with FEA, then delivered as manufacturing files. Need the machine itself? I can build it and ship it to you.
Send a sketch, a photo or an existing part. You get a clean parametric model, 2D technical drawings, assemblies, exploded views and a BOM.
From a photo of an old part to a DXF your laser can cut the same day: closed contours, true arcs, flat patterns with bend lines and K-factor, nested on your sheet size.
3D CAD and design for manufacturing of free weights, handles and cable attachments, with your branding, exploded views, BOMs and drawings ready for the factory.
Ultimate Leg Machine
01 — About
Highly technical, precise, and professional R&D Mechanical Design Engineer specializing in top-tier digital engineering solutions. I use advanced CAD and FEA tools to deliver production-ready designs for international clients and corporate partners — focused entirely on digital preparation, structural integrity validation, and Design for Manufacturing (DFM) principles.
Dassault Systèmes · SOLIDWORKS
Credly-verified credential demonstrating advanced proficiency in SOLIDWORKS part and assembly modeling, mating, and analysis tools.
Verify on Credly →Dassault Systèmes · SOLIDWORKS
Credly-verified specialty credential in SOLIDWORKS sheet-metal design — flat patterns, forming tools, and manufacturable bend geometry.
Verify on Credly →Dassault Systèmes · SOLIDWORKS
Credly-verified foundational credential covering core SOLIDWORKS part modeling, assembly and drawing skills.
Verify on Credly →ITIDA & EYouth · 2024
Certificate of Achievement — graduated from the 3-month ITIDA Gigs freelance training program, certified with the required skills to operate as a professional freelancer.
View Certificate →ITIDA · TIEC · Creativa Tanta Innovation Hub · 2024
Certificate of completion — Career Directions program by KenKo, hosted at Creativa Tanta Innovation Hub under ITIDA & TIEC. Completed December 24th, 2024.
View Certificate →
MAX MOVE · Fitness Equipment Manufacturer · Sadat City, Egypt
Engineering & Product Development — designing commercial strength equipment (plate-loaded and selectorized machines, cable systems, functional trainers) from concept to production-ready documentation: complete SolidWorks 3D models and assemblies, 2D manufacturing drawings, BOMs and cutting lists, validated with engineering calculations against technical, manufacturing and safety requirements. Remote (part-time → full-time) with scheduled factory visits for prototyping and manufacturing support.
Fiverr · Separate service
Beyond the design files, I now manufacture the gym machines I design for my Fiverr clients and ship them worldwide — offered as a separate service from the design work.
Rebuilt Company
Spearhead engineering & DFM of commercial fitness equipment — heavy-duty power racks and plate-loaded hip thrust machines. Validate structural integrity via FEA equivalent strain studies on welded frames and optimize sheet-metal nesting for laser-cut manufacturing.
ISM LTD
Full R&D focus on gym equipment design and biomechanics — integrating complex mechanisms into unconventional machine concepts, preparing manufacturing files, and drafting patent documentation for Saudi Arabia, ISO and broader Middle East approval.
Fiverr · Global
25+ specialized engineering projects for international clients — precise 3D models, FEA simulations and DFM optimizations across gym equipment, rehabilitation machines and home fitness equipment.
El-Nesr For Sheet Metal Cutting
Reverse engineered real-world sheet metal parts — measuring, drafting clean CAD geometry, and exporting production-ready DXF files. Owned the full nesting pipeline on plasma and laser CNC: layout optimization, G-code adjustment, and machine parameter tuning (cutting speed, kerf, pierce). Focused on cost reduction through aggressive nesting strategies that minimized scrap and maximized sheet yield.
Featured Shop Floor — El-Nesr For Sheet Metal Cutting
Tanta University
Multidisciplinary program combining mechanical design, electronics and control systems — kinematics, material science and structural analysis applied directly to R&D product development.
02 — Services
Two disciplines, one production pipeline — engineering the machine, then preparing every file the factory floor needs to build it.
Full mechanical design of gym machines and structural equipment, validated for real-world loads before a single part is cut.
Full CAD engineering of commercial fitness machines — power racks, plate-loaded machines, cable systems — built for duty-cycle durability.
Range-of-motion and joint-loading logic translated into mechanical linkages, resistance paths and frame geometry.
Equivalent-strain and static structural simulation on welded frames and brackets to validate strength before manufacturing.
Motion, tip-over and center-of-gravity studies to confirm equipment stays safe and stable under real loading conditions.
Clean, laser-ready and shop-ready files so what you approve on screen is exactly what comes off the machine.
A separate, optional service: once your design is done, I can manufacture the machine and ship it to you — wherever you are.
The same machine I engineered for you on Fiverr, manufactured directly from its production files.
CNC laser-cut parts, welded frames and a powder-coated finish — the full build, not just the files.
Packed and shipped to clients around the world, straight from the workshop.
Order the design files on their own, or add manufacturing and shipping as a separate step.
03 — Projects
Real CAD models from real projects — rotate through the machines, engineered from concept to manufacturing-ready.
04 — Built
My latest machine off the shop floor. Drag across the image to compare the CAD render with the real, manufactured build.
A one-off leg press made for a single child with muscular atrophy. The client sent me all of the child's body measurements, and I designed the machine specifically around him — then manufactured it from my own production files.
Sized from the child's own measurements, with a maximum working load of 3 kg — and up to 4 kg of extra weight can be added later.
Sheet-metal plates cut on CNC laser from DXF files, and the pipes cut on a rotary tube laser from IGES files.
The cut pipes welded together to form the machine's main frame.
Finished, assembled and standing on the shop floor — matching the render.
05 — Contact
Have a machine to design or files to prepare for manufacturing? Reach out through whichever channel works best for you.
