Professional Summary:

An experienced Mechanical Design Engineer with a track record of creating, analysing, testing and troubleshooting mechanical prototypes / gearing technologies to enable the development of cutting-edge products. Key strengths include: designing a wide variety of gearboxes, including very high torque wind turbines, automotive gearboxes and high-speed gas turbines; analysing product specifications and client requirements in order to prepare conceptual designs and fit-for-purpose solutions; conducting complex engineering calculations, interpreting designs and resolving engineering issues to ensure the on-time, on-budget delivery of prototypes; and managing clients during key project phases to facilitate seamless design processes and enable the delivery of world-class solutions.

Key Expertise:

§  Mechanical Engineering

§  Powertrain Engineering

§  Reverse Engineering

§  Prototype Development & Testing

§  Finite Element (FE) Analysis

§  Gearbox Problem Troubleshooting

§  Project Management & Delivery

§  Requirements Gathering

§  Technical Proposal Development

§  Client Relationship Management

§  Manufacturer & Assembly Support  

§  Design Solutions (3D CAD / ProE)  

Current Role:

August 1997 to date: Independent Contractor (WTC Transmissions Ltd)

§  Since 1997, have operated as an Independent Contractor / Consultant completing assignments for organisations, such as Andritz AG, Harper Adams University, Prodrive, Ricardo UK, Romax and Orbital2. Since 2000, I have rented an office locally where I have a full ProE (Creo) CAD & Promechanica licence. Below is a list of example assignments completed over this period (in no particular order and not all are listed).

Example Projects / Assignments:

Ricardo MTC: Motorbike Gearbox Design: Design Engineer (15 months)

§  Ricardo MTC secured a contract to design and prototype a new gearbox. Engaged to design 6-speed gearbox to fit into an existing 5-speed. Investigated concepts; evaluated designs and developed creative, multi-torque path gearbox; presented solution to Ricardo, eliciting feedback; produced detailed design concept and manufacturing drawings; played role in failure mode study with Harley-Davidson; and contributed to prototype testing. Succeeded in developing prototypes that passed testing and proved to be fit-for-purpose based on the original design.

Ricardo MTC: Hybrid Gearbox Design: Design Engineer (9 months)

§  Ricardo MTC were commissioned to design and prototype a hybrid epicyclic gearbox combining 2 electric motors and an IC engine for a Ford Mondeo. Engaged to lead design phase of this project. Gathered requirements; designed concepts for various gear arrangements, identifying best fit-for-purpose concept; designed gears and prepared detailed gearbox design; produced manufacturing and assembly drawings; and provided support during manufacturing phase. The hybrid gearbox design was completed successfully, meeting all packaging & interface requirements.

Compact Orbital Gears (COG): Wind Turbine Gearbox Endurance Design & Test: Project Manager

§  COG obtained a government grant to perform endurance testing on a previously designed wind turbine gearbox. As Project Manager, led endurance design & testing. Elicited requirements and reviewed gearbox drawings for test rig; designed back-to-back test rig and performed stress analysis; designed hydraulic system that dynamically simulated wind loads; combined hydraulic control and computer systems to provide test loads; assembled performance monitoring system; and conducted full endurance test, compiling and reducing data for final report. Succeeded in executing endurance testing and providing the client with relevant performance data.

Harper Adams University: Prototype Differential Gearbox (24 months)

§  Harper Adams University required a differential gearbox for the development of a hybrid agricultural vehicle. Engaged to create conceptual design, manufacture and assemble prototype. Developed preliminary concept and detailed design applying flexible planet pin technology; performed gear train analysis to verify design; created detailed manufacturing drawings; liaised with manufacturers to secure customised parts; and assembled / tested design at customer facility. Succeeded in designing, manufacturing, assembling and testing the prototype which earned complete customer approval.

Andritz AG: Centrifuge Gearbox Design (24 months)

§  Andritz wanted to replace hydraulic units of centrifuges with a gearbox to improve utilisation and manufacturing cost efficiency. Engaged to design high-ratio, high-torque, high-speed rotating gearbox. Elicited client requirements; created conceptual designs using PTC Creo CAD; developed gear design with KiSSsoft software; performed stress / vibration simulation analysis of casings, couplings bearings, seals and oil distribution systems using PTC ProMechanica FE analysis; and created assembly drawings, parts lists and 3 assembly manuals. Design was completed, resulting in a provisional patent. Now pending manufacture and testing.

Romax Technology: CVT Gear Casings Design (12 months)

§  A Romax customer needed gear casings designed for a CVT transmission, including mechatronic valve block, provided by a Japanese truck manufacturer. Engaged to design necessary gear cases. Met with client to scope requirements; reviewed client’s CAD files and designed casings to fit with client’s truck and gear designs; conducted ProMechanica FE analysis on casings to support personally created design; and created detailed manufacturing drawings of casings and models for castings manufacture. Successfully completed gear casings design which were manufactured and are currently undergoing prototype testing in Japan.

Prodrive: Torque-Vectoring Transmission & Differentials Design: Principal Design Engineer (8 months)

§  Prodrive was commissioned to develop a World Rally Car (WRC) requiring an innovative torque-vectoring 4WD transmission. Engaged to design torque-vectoring differentials, clutch housing and gear casings for gearbox. Liaised with Prodrive and customer to elicit requirements and packaging constraints; designed clutch housing and gear casings; conducted structural analysis of casings & shafts; and prepared manufacturing drawings. Succeeded in designing transmission casings and differentials which led to the development of mock-ups that were fitted to the WRC.

Orbital2: Wind & Marine Turbine Gearbox Designs: Design Engineer (5 years)

§  As a new start-up, Orbital2 required gearbox engineering design support for new wind and marine turbines. Engaged to design & prepare proposals. Developed initial ProE designs and PowerPoint proposals to outline various concepts for gearboxes; prepared detailed designs; performed FE analysis on casings, bearings and structural parts; and created manufacturing drawings. Produced concept designs that became integral in Orbital2’s early development and positioned the company as an established player in the field of wind and marine turbine gearboxes.

Career History:

§  01/2016 to 03/2016:  Ricardo: Design Engineer (contract)

§  09/2015 to 01/2016: Torotrak: Design Engineer (contract)

§  04/2015 to 09/2015: Ricardo: Design Engineer (contract)

§  01/2013 to 02/2015: Andritz AG: Design Engineer (contract)

§  08/2014 to 12/2014: Ricardo: Design Engineer (contract)

§  01/2003 to 10/2014: RJ Hicks: Design Engineer (contract)

§  06/2012 to 08/2013: Harper Adams University: Design Engineer (contract)

§  06/2012 to 04/2013: Romax Technology: Design Engineer (contract)

§  01/2011 to 05/2012: WinWind: Design Engineer (contract)

§  03/2010 to 12/2010: Antonov: Design Engineer (contract)

§  09/2009 to 03/2010: Ricardo: Design Engineer (contract)

§  09/2003 to 01/2009: Orbital2: Design Engineer Consultant (contract)

§  01/2001 to 08/2007: Ricardo MTC: Design Engineer (contract)

§  03/2000 to 12/2000: Prodrive: Principal Design Engineer (contract)

§  06/1998 to 03/2000: Ricardo MTC: Design Engineer (contract)

§  08/1997 to 06/1998: Lucas Flight Controls: Conceptual Design Engineer (contract)

§  06/1995 to 08/1997: JCB Transmissions: Senior Mechanical Design Engineer (perm)

§  07/1991 to 05/1995: Compact Orbital Gears: Design & Project Manager (perm)

§  10/1988 to 06/1991: Teldix GmbH: Mechanical Design Engineer (contract)

§  03/1987 to 06/1988: Diehl GmbH: Mechanical Design Engineer (contract)

§  02/1985 to 12/1986: Technische Physische Dienst: Mechanical Design Engineer (contract)

§  07/1978 to 02/1985: British Aerospace Dynamics Group: Senior Design Engineer (perm)

Qualifications:

§  BSc in Mechanical Engineering (2:2): The Hatfield Polytechnic

§  Council for National Academic Awards (CNAA): Sponsored by British Aerospace

Technologies:

§  Solid-Edge, CADDS5, UG vNX4, CATIAv5, AutoCAD, MEDUSA, CADAM, KISSsoft, COG, Mathcad, MITCalc, TK Solver, TK Gear, Pro/E / PTC Creo, Mechanica / Simulator FEA, Microsoft Office

Awards:

§  Design Council: 1^st Prize for Design

§  Worshipful Company of Turners: 3^rd Prize for Design

§  Dutch Science Council: Award for achieving tight delivery schedules

§  BAe: 1^st Prize Undergraduate Report

Personal Details:

§  Consulting Business Address: Unit 1, Antur Gwy Business Centre, Park Road, Builth Wells

§  Home Address: 31 Lakeside Avenue Llandrindod Wells Powys, LD1 5NT

§  Driving Licence: Full UK (clean)

Recommendations:

“Geoff has been extremely helpful to us at Harper Adams University ... his knowledge in the design and manufacture of gearbox systems has enabled us to compete research activities that would have been impossible without him. I cannot endorse his knowledge and support more highly.” Dave Allan, Senior Lecturer, Harper Adams University

“I have known Geoff for a number of years, having worked previously when employed by Ricardo. I have always found him to be professional and committed to delivering a quality solution within the agreed time.” David Saysell, Team Leader Design & Analysis, Romax Technology Ltd

“Geoff is a dedicated expert in his field, and a good friend ... always looking at new ideas. In the latest project for the design of a special gearbox, he showed great involvement and contributed to several new ideas. I would happily hire him again based on the high value he has delivered.” Jan Michelsen, International Product Manager, D-type Decanters, Andritz