Hire the Best Finite Element Analysis Specialists
in the United States

I bridge the gap between concept and commercial reality. As a US-based Mechanical Engineer with 6+ years of experience, I engineer shop-ready products that work in the real world and in simulation. I help entrepreneurs and US manufacturers eliminate costly fabrication errors, optimize production cycles, and navigate the complex path from napkin sketch to mass production. Why Clients Choose Me Over Offshore Alternatives: US-Based & Compliant: I operate in your time zone and am fully qualified for IP-sensitive projects. Your intellectual property never leaves US jurisdiction, ensuring maximum security. ⚙️ Shop-Floor Fluency: I speak the language of machinists and mold makers. My designs are built with Design for Manufacturing (DFM) at the forefront, ensuring you don't pay for features that can't be machined. 📉 Capital Efficiency: I use advanced simulation (FEA & CFD) to validate designs virtually, reducing the need for expensive physical prototype iterations. My Core Engineering Solutions: 1. Design for Manufacturing (DFM) & Assembly The Goal: Reduce unit cost and tooling complexity. The Process: Rigorous analysis of wall thickness, draft angles, and tolerances (GD&T) for Injection Molding, CNC, and Sheet Metal. I deliver files that machine shops accept without questions. 2. Concept-to-Reality Product Design The Goal: Transform vague ideas into functional products. The Process: Full-lifecycle development using Fusion 360. From complex mechanism design to aesthetic enclosures, I create parametric, editable assemblies ready for future iteration. 3. Risk Mitigation via Simulation (FEA) The Goal: Prevent field failures. The Process: Structural Optimization & Analysis to predict failure points before cutting a single piece of material. What My Clients Say: "Sebastian’s attention to detail... reduced total manufacturing time by hours; this project has truly changed my life." - LOBA Corporation "The simulation insights were invaluable, and the detailed presentation made everything clear." - DBS Studio Ready to engineer a product that lasts? Click the green "Invite" button to discuss your project requirements. I typically reply within 60 minutes during US business hours.

I bridge the gap between rigorous engineering physics and fast-paced product development. As a PhD Mechanical Engineer and startup founder, I offer a rare combination of deep theoretical knowledge and practical, hands-on building experience. I don't just design parts in CAD. I engineer complete systems by handling the mechanical design, optical integration, thermal analysis, and the Python code that makes it all run. Whether you need to design a rugged sensor enclosure, automate a testing setup, or model a complex physical system, I bring the "Founder’s Mindset" to your project. I prioritize robust, manufacturable solutions that fit your timeline and budget. My Multi-Disciplinary Expertise: 1. Mechanical Engineering & DFM I take concepts from napkin sketches to mass production. My designs are built for the real world, not just the computer screen. Tools: Expert in SolidWorks and Fusion 360. Capabilities: Design for Manufacturing (CNC, Injection Molding, 3D Printing), GD&T, and complex assembly management. Experience: Engineered high-pressure sensor housings (10,000 psi / 250°C) and solar concentrator modules that survive outdoor elements for 20+ years. 2. Optomechanics & Precision Instrumentation: If your product involves light, lasers, or sensors, I am the specialist you need. I understand how mechanical stress affects optical performance. Experience: Designed and built a sub-micron alignment workstation for fiber-to-chip attachment using high-power CO2 lasers. R&D: Developed novel photonic sensors (published in Seismological Research Letters and Applied Optics), proving my ability to develop and handle extremely sensitive instrumentation. 3. Engineering Computation (Python & FEA) I use code and simulations to validate hardware. I rely on calculation rather than guesswork. Simulation: Advanced Finite Element Analysis (ANSYS/COMSOL) for thermal, structural, ray/wave optics and multiphysics problems. Python: Proficient in NumPy, SciPy, and Pandas for data analysis and physics-based modeling. Automation: I build custom GUIs (Tkinter) to interface with hardware and automate data acquisition. Why Clients Trust Me: I have built my own company: As a founder in the renewable energy sector, I treat your capital with the same respect I treat my own. I focus on viable, scalable engineering. I solve the "Hard" problems: I specialize in projects where standard engineering isn't enough, such as those involving extreme temperatures, high pressures, and sub-micron tolerances. If you need a partner who can see the whole picture, from the mechanical system to the physics inside, click "Invite to Job" and let’s discuss your project.

Great products begin with a great design that includes considerations for realistic fabrication and assembly. My history of deep involvement with a variety of manufacturing methods allows me to incorporate a long-term vision of the product life cycle throughout the design process. This constant forward-thinking prevents major redesign during the manufacturing phase and ensures projects remain aligned with customer goals. I specialize in 3D mechanical design, analysis and prototyping including: - Design-for-manufacture using: 3D print, CNC machine, injection mold, die cast, sheet metal, laser cut, etc. - Electronics integration - Structural/thermal/vibration analysis - Prototype manufacturing & assembly - Mechanical drawing package creation - Production interfacing I have designed, built and tested successful (some patented) products in the following industries: - Mechanized medical devices - Medical research test equipment - PCB & housing assembly tooling - Aerospace test equipment - Aerospace showroom cabin interiors - SCUBA diving propulsion - Underwater electronics enclosures - Bicycle lights - Photography lights and straps - Mechanized sports training equipment - Small satellite structure & hardware - High-altitude passenger vessel

Transform your product ideas into optimized, manufacturable designs using advanced engineering and data science. What I deliver: • Design Optimization: Reduce costs and improve performance using genetic algorithms, FEA, and multi-objective optimization • Parametric CAD Modeling: Create flexible, modification-friendly designs in Fusion 360 that adapt to changing requirements • Data-Driven Engineering: Apply Python-based analysis to solve complex design problems and validate performance • Reverse Engineering: Recreate and improve existing products when documentation is unavailable Highlighted Results: ✓ Created a custom genetic algorithm to optimize component placement in electronic test fixtures, handling hundreds of design variables while respecting complex geometric constraints ✓ Developed method for measuring the flexural strength of fiberglass composites with complex shapes that are not suited to traditional 3-point-bending methods ✓ Designed spouts for luxury water features, focusing on lost-PLA casting and machining methods My Background: MS Mechanical Engineering with thesis on advanced geometric analysis. 5+ years optimizing designs for cost, performance, and manufacturability. Ready to optimize your next project? Let's discuss your specific challenges.

*** To Clients: Scammers on Upwork impersonate me and other professional engineers. PLEASE INTERVIEW YOUR PROSPECTS IN A **VIDEO CALL** to make sure they are real and ask them to provide credentials. As professional engineers, our information is public and anyone can claim they are us! *** I am Hady Makhmalbaf, Ph.D., P.E., a licensed mechanical engineer in Detroit Metro, Michigan with over 13 years of experience in the industry and 9 years in academia in various fields of mechanical engineering. As a senior mechanical engineer, I have worked for well-known engineering firms in Michigan as well as some overseas companies. Between 2011 and 2021 I worked for Western Michigan University as adjunct faculty, research scientist and teaching assistant. I have also been an active member of ASME, ASHRAE, ASPE and APS for several years. If you would like further information about my background and expertise, feel free to visit my LinkedIn profile (Please Search for "Hady Makhmalbaf") and my Google Scholar page (Search for "Mohammad Hady Makhmalbaf"). A team of 3 engineers are working with me and can provide the following engineering services with high level of quality, precision and professionalism: 1- Computational Fluid Dynamic (CFD): (flow model, turbulence, heat transfer, thermal analysis) -Software: ANSYS Fluent, CFX, OpenFoam and COMSOL. 2- Plumbing, Heating, Ventilation and Air Condition -Software: HAP, CAD, REVIT, CAPS, TEAMS, RS MEANS, etc. 3- Design, Calculation, 3D modeling, Detailing and Stress Analysis of Steel Structures and Mechanical Components -Software: Auto CAD, Solidworks, Tekla Structure, SAP 2000, Abaqus, CATIA V5. 4- Thermal and mechanical design of storage tank, heat exchanger. Software: Aspen, PV elite. I will be available for phone and video interviews and business meetings 8 a.m. to 6 p.m. EST. If you are in different time zones and this time frame does not suit you, meetings outside this window can be scheduled. As my Upwork profiles shows, our goal is to provide high quality service in a timely manner with 100% job satisfaction for a fair price. Looking forward to having business with you.

I have 25 years of experience in applying physics-based methods (such as CFD, FEA, heat transfer, turbulence, mass transfer, bio-reactions, and chemistry), hand calculations, testing techniques, and statistical analysis across diverse industries, including aerospace, medical, semiconductor, apparel, footwear, gloves, automotive, and chemical processing. My expertise spans from concept development to prototype creation and commercial launch, with a focus on scaling processes and equipment from prototype to commercial scale. Many of these product developments are supported and validated by tests conducted in a cost-effective, technically balanced manner. I address significant uncertainties by making well-considered assumptions and approximations, often solving simplified 0D, 1D, 2D, or simplified 3D models with enough physics to guide product development, rather than solving the most complex real 3D geometries. I have worked with tools such as ANSYS Fluent, CFX, STAR-CCM+, CFD-ACE+, TAITherm, OpenFOAM, and ANSYS Mechanical for various applications. Key Contributions: • Collaborated with test and design engineers in developing next-generation engines for launch vehicles and spacecraft, including systems such as thrust chamber cooling, fuel/oxidizer pressurization, fuel tank filling and emptying, manifolds, injectors, diffusers, flow straighteners, and cavity purge analysis, using STAR-CCM+ and ANSYS Fluent. • Supported test campaigns, integrating CFD analysis with hotfire test data and ensuring the digital twin remained up to date. • Led component, subsystem, and product-level simulations to support design, development, verification, and validation efforts, ensuring performance in intended environments and conditions. • Developed thermal analysis models using ANSYS, STAR-CCM+, ACE+, and MSC Patran at various levels, including components, multichip modules, circuit card assemblies, subsystems, and systems, resulting in low thermal-risk hardware. • Created test plans and procedures that led to successful execution and results. • Identified and tested advanced thermal interface materials (TIMs). • Performed thermal analysis model correlations to refine predictions based on test data, enhancing understanding and accuracy. • Worked closely with customers and engineering teams to define the necessary testing to validate thermal analyses and ensure compliance with requirements. • Applied hand calculations and ANSYS Fluent thermal analysis to guide the design of evaporators and cooling plates. • Optimized advanced IC designs to ensure optimal thermal performance. • Utilized aerogel-based insulation composites to mitigate hotspots and meet touch safety requirements. • Conducted thermal analysis for fire testing of building construction and materials.