Hire the Best Finite Element Analysis Specialists
in the United States

A bottom-line business-minded mechanical engineer with a constant record of achievement through 16 years of increasing profits and reducing costs through an inventive, optimized, & efficient approach to engineering solutions.  Having earned a combined MS & BS and a P.E. License in mechanical engineering and earning the highest level of certification in SolidWorks, I bring comprehensive expertise in mechanical design, analysis, document administration, management & leadership of projects, and exceptional service to my customers  An understanding of people and how to communicate with them and ascertain their needs, whether customer, peer, supervisor, or manager, for a positive interaction and satisfying outcome  16 years as mechanical engineer interfacing with internal & external customers needing expert 3D CAD, product design, GD&T drafting, FEA, simulation, & computational capabilities  Diverse background in Bulk Materials, Defense, Aerospace, Manufacturing, 3D Printing, and Plastics Extrusion, ready to interface with customers and apply engineering principles to serve client or employer needs in any engineering field  Talented 3D CAD design specialist utilizing GD&T, FEA, CFD, surface modeling, and material behavior experience with ability to optimize, troubleshoot and integrate solutions  Small business owner partnering with firms providing critical insight with analysis, manufacturing feasibility, & creative design  Experienced drafter and auditor providing proven results in quality control of engineering drawings before they reach manufacturing  Seasoned design-for-manufacturing mentality, taking ideas from concept to production Led KULR engineering team as lead Senior Mech. Engineer & SolidWorks PDM Administrator. Organized company file structure & designed efficient CAD workflow and engineering operations to meet auditing criteria. Designed PPR grade battery systems for aerospace, drone, subsea, and niche customers and provided engineering guidance to all personnel. (2024 – present). • Responsible for successful design & manufacture of liquid oxygen and liquid natural gas Ducts & Lines on four development and production units of Blue Origin’s BE-4 engine over 6-month contract period. (2022) • Transformed Violett’s Luminair air purifier from a 3D printed prototype to a refined injection molded product, with improved & more cost-effective features & enhancements. Performed complex CFD, detailed injection molding design, produced manufacturing packages. (2021-2023) • Joined startup Tiberius Aerospace in to produce an industry-changing VTOL aircraft. OML, structural, and component/ systems layout design, modeling and analysis. As lead engineer, used SolidWorks & Catia V5 to model unique aircraft configuration. Performed stress analysis based on projected boundary condition loads, using results to optimize structural member profile & path. Designed modular ground test unit to capture raw data from all aspects of VTOL flight system. • Took the Gateview Technologies data center rack PDU line from hundreds to thousands of purchasable configurations with new features. Joined their team as Lead Mechanical Engineer responsible for developing and managing product line. Managed and trained junior employees in engineering practice and techniques. Developed & designed configurations with integrated control to SolidWorks in MS Excel, to include mechanical, electrical, and BOMs. Produced vendor BOMs and manufacturing drawings for the entire product line. Effort included injection molding design, sheet metal design, optimization of component placement, PCB layout, wire routing in CAD. • Joined the NASA JETS contracting team at Jacobs Engineering & HX5 as a lead CREO engineer designing, analyzing, and testing engineering designs on the latest iterations of the xEMU project PGS, PLSS, and INFO subsystems of the NASA astronaut spacesuit and the ISS payloads for space flight extra-vehicular activity (EVA). (2017 – 2021) • Reorganized and restructured Inline Inspection Tool product line of Envirocal, Inc. as Engineering Project Manager. Restructured and fixed components and assemblies files of their SolidWorks files, adding metadata to properly automate BOM creation. Created fabrication- and procurement-ready drawing packages (assembly exploded views, full BOMs, complete part details & dimensions) for each of their inspection tool sizes. (2019) • Joined the Flexible Lifeline Systems team as part of the 3-man engineering group responsible for transforming the company from a custom fabrication job shop into an engineered modular and catalog-part manufacturing facility, turning a dying business into a multi-million dollar company. (2016-2017)

Hi, I'm Mike, founder of End Effect LLC. I have 15+ years of experience in manufacturing and hardware design, in both R&D and production environments. I am a certified Solidworks Expert and can quickly help bring your concepts to life, or refine an already existing process, product, or workflow. My experience across different industries and my diverse hands on manufacturing experience allow me to help design your product with quality, budget, and timeline in mind. Clear and active communication, first class service, and sustainable solutions for my clients are the pillars of my work. If you have a product or project you need help with, feel free to reach out! SERVICES OFFERED: ✅ 3D design in Solidworks, including machines, mechanisms, tooling, structures, and more ✅ Process development, work cell design, and continuous improvement through 5S and LEAN ✅ Reverse engineering, 3D scanning, and optimizing for functionality and manufacturing ✅Structural, modal, thermal, and other FEA analyses, as well as motions studies ✅ Sourcing vendors for prototyping or high volume manufacturing ✅ Writing and conducting test plans to validate new products or processes ✅Creating manufacturing-ready drawings and work instructions ✅ Project management and general engineering consultations INDUSTRIES SERVED: - Aerospace - Industrial - Consumer Products - Energy - Medical Device MANUFACTURING METHODS I CAN DESIGN FOR: - CNC Machining - Welding - 3D Printing - Injection Molding - Extrusion and Pultrusion - Urethane Casting - Waterjet & Plasma Cutting - Sheet Metal - Composites - And more...

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.

As a highly experienced Senior Mechanical Engineer with a track record spanning over 15 years, I have successfully navigated many different industrial domains. My mission is to leverage this wealth of engineering expertise to deliver premium consulting services, encompassing everything from design to creation of concept-to-manufacture schematic drawings, FEA analysis, and comprehensive Design for Manufacturability (DFM) insights. My proficiency extends to various SolidWorks certifications. With a proven ability to excel across a wide spectrum of industries, I invite potential clients to peruse my portfolio. I look forward to connecting with you and/or your company to understand your specific goals and collaborate on tailored solutions that will drive your success to new heights.

I am a highly specialized Computational Engineer operating at the intersection of Aerospace Engineering, Computer Science, and Machine Learning. I excel at translating intricate engineering logic into high-performance, automated operational strategies, ensuring rigorous standards in code validation, hardware integration, and simulation accuracy. What I Do Best: Engineering Simulation & Modeling: Deep expertise in developing parametric verification suites, automated structural/fluid load calculations, and mass estimation processes utilizing MATLAB & Simulink. AI & Machine Learning Integration: Proficient in building high-quality technical datasets, neural network training pipelines, and custom evaluation rubrics using Python (Scikit-Learn, PyTorch) and C/C++. Rapid Prototyping & Embedded Systems: Comprehensive hands-on experience taking hardware projects from concept to physical execution. Expert in CAD modeling (SolidWorks/AutoCAD), 3D printing optimization, laser cutting, and microcontroller firmware debugging. Technical Advisory & Logic Validation: Proven track record of providing code reviews and architectural troubleshooting for over 1,000+ engineering prototypes, prioritizing safety-critical execution and optimal runtime. Whether you need to build high-performance data pipelines, model complex physical systems, or validate embedded hardware logic, I deliver premium, production-ready solutions. Let’s connect to discuss your project requirements and elevate your technical infrastructure.

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.