Hire the Best Finite Element Analysis Specialists
in the United Kingdom

Mechanical Design Engineer with 44,000 hrs DFM multi-industry experience of special purpose machinery, automated equipment & bespoke devices, including steel fabrications & precision machined components. Educated to B.Eng. Honours Degree in Mechanical Engineering. Comprehensive mechanical engineering designs generated from design brief or concept through to complete manufacturing drawing and documentation package. As well as mechanical calculations.

Tom Dornom - TOP RATED About Me: I'm a Chartered Engineer with a passion for CAD design. With a background in mechanical engineering and a wealth of experience, I'm here to bridge the gap between creativity and technical precision. Here's what you can expect: Expert CAD Services: As a Chartered Engineer, I offer top-tier Computer-Aided Design services. Whether it's 3D modelling, product development, or product design, I bring an unparalleled level of expertise to every project. Precision and Quality: My work is synonymous with precision and quality. Every CAD design I create is meticulously crafted to meet industry standards and your specific requirements. Customized Solutions: I understand that each project is unique. I excel in tailoring CAD solutions to your exact needs, ensuring that your vision becomes a reality. Professionalism: My commitment to professionalism means that you can trust in my work ethics, adherence to deadlines, and clear communication throughout our collaboration. Credentials: As a Chartered Engineer (CEng MiMechE), I bring not only the skills but the credibility and expertise that your project deserves. Innovation: I'm dedicated to staying at the forefront of CAD technology and trends to provide you with the latest and most innovative solutions. Let's Connect: I'm ready to work with you on your next CAD project. Let's bring your ideas to life with precision and innovation.

I am a vibration and FEA expert with 10 years of professional experience. I hold a PhD in Structural Dynamics and I am a Chartered Mechanical Engineer (CEng MIMechE). I diagnose vibration issues, validate structures with FEA, and optimise mechanical designs for strength, durability, and reliability using advanced engineering simulations. I deliver clear reports, data-driven insights, and practical recommendations, giving you the confidence to make safe and efficient engineering decisions. ⚙ Vibration Engineering & Dynamic Analysis ⚙ ✔ Vibration troubleshooting & resonance control: resonance mapping, mode tuning, root-cause diagnostics ✔ Modal analysis, EMA/OMA & testing: damping estimation, mode-shape interpretation, shaker campaigns, sine/random vibration, shock testing ✔ Signal processing & data interpretation: accelerometer-based insights, FFT, waterfalls, envelope methods, feature extraction, spectral analysis, DAQ and test-setup planning ✔ Python for vibration analysis: automated diagnostic pipelines and ML-based anomaly detection ✔ R&D support and development of clients’ in‑house vibration analysis capability ✔ Design optimisation for vibration performance: stiffness tuning, mass distribution, damping and dynamic response refinement ⚙ FEA: Static, Transient & Fatigue Analysis ⚙ ✔ FEA for structural integrity: strength, stiffness, stability, and deformation under realistic loading ✔ Transient FEA: impacts, shocks, rapid load changes, and start-up/shutdown events ✔ Non-linear FEA: contact, plasticity, material nonlinearity, and large-deformation behaviour for complex structures ✔ Fatigue & durability prediction: stress-life and strain-life methods to reduce failure risk and extend service life ✔ Design optimisation: eliminate hotspots, improve stiffness, and increase overall reliability ✔ Salome_Meca, Code_Aster and Paraview user ⚙ Rotordynamics & High-Speed Machinery FEA ⚙ ✔ Critical-speed and stability assessment for pumps, compressors, turbines, and other rotating machinery ✔ System-level rotordynamics evaluation: Campbell/Bode analysis and run-up / coast-down behaviour for multi-stage rotors, pump trains, and rotor-bearing systems ✔ FEA for rotating components: blades, impellers, rotors, couplings, and high-speed assemblies assessed for stiffness and deformation control ✔ FEA for static components: casings, housings, pump volutes, bearing pedestals, and structural frames analysed for load transfer, thermal effects, and long-term reliability ✔ Design refinement for rotating machinery: mass-stiffness balancing, blade/impeller geometry tuning, and structural improvements that enhance performance and reduce maintenance issues ⚙ CFD (Computational Fluid Dynamics) ⚙ ✔ Flow performance analysis: pressure, velocity, and flow-distribution insights for ducts, manifolds, nozzles, and mechanical systems ✔ CFD for pumps & turbomachinery: impeller/volute flow behaviour, hydraulic efficiency, cavitation risk, and blade-passage optimisation ✔ Pressure-drop & flow-resistance evaluation: system-level assessments to reduce losses and improve efficiency in pipework and mechanical assemblies ✔ Design improvements from CFD results: geometry adjustments, smoother flow paths, reduced recirculation, and enhanced performance ✔ OpenFOAM user ⚙ CAD / Mechanical Design Modifications ⚙ ✔ Structural refinement & geometry optimisation: ribbing, filleting, thickness tuning, load-path improvements, and mass redistribution to eliminate stress hotspots ✔ CAD updates: translating engineering recommendations directly into updated CAD models ⚙ What I Bring to Your Project ⚙ ✔ Highest engineering standards – I adhere to recognised engineering codes of ethics and avoid pirated software, half-ready solutions, or any practices that could compromise your project. ✔ Clear communication & responsiveness – fast replies, transparent progress updates, and clear explanations of technical topics. ✔ Actionable outputs & implementation support – practical recommendations you can apply immediately, plus guidance during and after the project. ✔ Reliable delivery – on time, within budget, and to the agreed technical quality. ⚙ Typical Deliverables ⚙ ✔ Action-oriented engineering reports – clear conclusions, safety margins, and practical recommendations (typically 5–12 pages, concise and decision-ready). ✔ Vibration & rotordynamics outputs – Bode/Campbell diagrams, frequency spectra, waterfall plots, and ODS/modal shapes with safe-operating ranges and tuning advice. Typical outcome: vibration reductions of 40–70% in problematic speed bands after design, support, or balance adjustments. ✔ FEA results & design changes – stress/fatigue plots, modal frequencies, safety-factor maps, stiffness checks, and targeted geometry up ➡️ Get in touch if you’d like an initial review of your vibration or FEA challenge — we can discuss the best approach by chat or jump on a short intro call ➡️

CAD design, FEA, CFD and heat transfer specialist, offering the complete project service from initial concept to final drawings. I have experience in Automotive and Aerospace design, Electronics and E-Machine cooling, as well as Thermo-mechanical analysis. 17 years CAD experience with Catia v5, 8 years CFD with Openfoam, working in the Formula 1 Aerodynamic Departments of McLaren, Honda, Brawn, Mercedes and Toro Rosso. An expert in aerodynamic surfacing for performance and aesthetics, packaging and cooling the driver, engine and electronics, and component design for wind tunnel model and full size car. Many of my recent projects involve electric vehicles: ground up design of last mile delivery vans and UAVs; electrification of snowmobiles, motorbikes, and boats. I offer the complete service of concept design, aero, thermal and structural optimisation, to final part drawings.

✅ Certified SolidWorks CAD Professional (CSWP) ✅ Specialist in Injection Molding & Plastic Product Design ✅ 200+ Successfully Completed 5⭐ Projects ✅ Award-Winning Product Designer ✅ Master’s Degree in Mechanical Engineering ✅ Designed Multiple Best-Selling Products in the Market ✅ Worked on 2 x Dragons Den Products (UK's Shark Tank) 🏆 About Me I am a highly experienced Mechanical Design Engineer & Industrial Product Designer with a proven track record of turning concepts into fully manufacturable products. With over 15 years of CAD expertise, I specialize in injection molding, plastic part design, and manufacturing optimization. I work with entrepreneurs, startups, and established businesses to bring innovative ideas to life. Whether you need a simple component design, a market-ready product, or a fully engineered complex mechanism, I provide cost-effective, custom-fit solutions to help you succeed. 🤖 AI-to-DFM Expertise Beyond traditional CAD and engineering, I also specialize in converting AI-generated ideas (ChatGPT, MidJourney, DALL·E, etc.) into manufacturable designs. I bridge the gap between creative AI outputs and real-world engineering, ensuring concepts are translated into CAD models optimized for materials, tolerances, and manufacturing processes - ready for prototyping and mass production. 🔹 My Expertise ✔ Concept Development & Product Design ✔ Computer-Aided Design (CAD) – SolidWorks, CATIA ✔ Injection Molding & Plastic Manufacturing Optimization ✔ Design for Manufacturability & Assembly (DFM/DFA) ✔ Finite Element Analysis (FEA) & Structural Simulations ✔ Mold Flow Analysis for Plastic Components ✔ High-Resolution 3D Printing (SLA), Pressure Forming & Silicone Molding ✔ Prototyping & Manufacturing Support (UK, China, Global) ✔ Photo-Realistic Renderings & Product Animations ✔ Converting AI / Images to Fully Designed for Manufacture Products (DFM) 🛠 Manufacturing & Engineering Expertise I have in-depth experience designing for a range of manufacturing processes, including: 🔹 Injection Molding (Plastic, Silicone, MIM, CIM, Overmolding, Insert Molding) 🔹 3D Printing (SLA, SLS, FDM, MJF, DLP) 🔹 Die Casting, Sheet Metal, CNC Machining, Extrusion 🔹 Blow Molding, Vacuum Forming, Rotational Molding 📢 Industry Experience I have worked across diverse industries, including: ✔ Medical Devices & Healthcare (Surgical Robots, Rehabilitation Equipment) ✔ Automotive & Motorsport (Prestigious Car & Vehicle Manufacturers) ✔ Consumer Electronics & IoT – Smart devices, enclosures, wearables ✔ Retail, Cosmetics & POS Displays – L’Oreal, Maybelline, NYX, Max Factor, Essie ✔ Robotics, Toys, Gaming, Sports & Fitness Equipment ✔ Drones, Aerospace, Defense & Marine Applications 🌍 Global Manufacturing Network I collaborate with trusted manufacturing partners in the UK, China, and worldwide, ensuring seamless prototyping and production. Whether you need low-volume prototypes or mass production, I provide cost-effective solutions tailored to your needs. 💡 Why Work With Me? ✅ Proven Success: Worked alongside experts from NASA, Dyson, and leading innovators ✅ Full-Process Support: From concept development to production ✅ Precision & Quality: Designs that minimize material waste & manufacturing costs ✅ Reliable & Communicative: Clear, professional collaboration throughout the project 📩 Let's bring your product idea to life! Contact me today to discuss your project.

Engineering is easy to describe when everything works on paper. The real challenge begins when a concept must survive manufacturing constraints, real-world operating conditions, cost limitations, assembly realities, and long-term performance expectations. Our team specializes in transforming complex engineering concepts into practical, manufacturable, and production-oriented solutions across multiple industries. Over the years, we have worked on projects involving CAD development, CFD and FEA analysis, enclosure and mechanism design, HVAC systems, injection molding, industrial automation, fluid systems, and manufacturable product engineering for both prototype and production-stage applications. Our workflow is structured around specialized engineering coordination rather than a one-person approach. Depending on the scope of the project, different engineering specialists may be involved during various stages such as concept development, simulation, DFM review, manufacturing preparation, prototyping, and technical validation. This allows each part of the project to be handled by the most suitable technical expert while maintaining organized communication and project continuity throughout the process. We place strong emphasis not only on engineering performance, but also on real manufacturability, assembly feasibility, supplier compatibility, serviceability, and long-term reliability. Many engineering concepts look promising in CAD renders or simulations but become difficult, expensive, or unstable once they reach production. Our goal is to reduce those risks early in the development process. In addition to engineering and simulation support, we also work closely with manufacturing workflows and production-oriented decision making. This includes design optimization for CNC machining, injection molding, sheet metal fabrication, 3D printing, assembly integration, tolerance considerations, and production preparation depending on the project requirements. Our approach is direct, detail-oriented, and focused on solving engineering problems in a realistic and structured way rather than overcomplicating the process with unnecessary theory or generic outputs. If you are looking for a team that can support your project from concept development to engineering execution with a practical and production-focused mindset, we would be happy to discuss your project further.