Mechanical Engineer | CFD · FEA · CAD | 2× USPTO Patents | Top Rated Plus
Overview:
Mechanical engineer specialising in CFD, FEA, and thermal systems, with two granted USPTO patents in cooling technology (US 12,452,991 · US 12,453,048). I design and validate heat exchangers, HVAC systems, centrifugal fans, and refrigerant loops in OpenFOAM, ANSYS Fluent, SimScale, and SolidWorks Flow Simulation. Top Rated Plus on Upwork , 85+ contracts, 3,000+ hours, $275K+ earned. Based in Cape Town, South Africa. Former CTO of a product development company.
I don't ship black-box "trust me" reports. Every deliverable carries the mesh, Y+ verification, residual history, and flow-uniformity evidence behind the numbers. Results your team can defend in a design review. And because I've built a Python+OpenFOAM automation pipeline, I run parametric sweeps hand-meshing freelancers can't: on Heat exchanger contracts(2026), a 224,000-point overnight sweep on a centrifugal heat exchanger surfaced a geometry that more than doubled system COP.
Core Services
CFD: heat exchangers, HVAC, centrifugal fans, ducts, refrigerant loops; conjugate heat transfer, natural convection, multiphase flow with species transport, turbulence modelling (k-ω SST, realizable k-ε, LES where warranted).
FEA / Structural: stress, fatigue life, vibration, drop/impact testing, nonlinear and topology optimisation, composites (CalculiX, ANSYS Mechanical).
Acoustic / NVH: noise prediction and NVH analysis.
CAD & Documentation: SOLIDWORKS parametric modelling, assemblies, sheet metal, weldments, surface modelling, photorealistic rendering, and manufacturing-ready technical drawings.
Software: OpenFOAM, ANSYS Fluent, ANSYS Mechanical, SimScale, STAR-CCM+, COMSOL Multiphysics, SolidWorks (CAD + Flow Simulation), CalculiX, Gmsh, AutoCAD, Fusion 360, MATLAB, Python.
Selected Work:
Heat exchanger (2026) — 224k-point automated CFD sweep on a centrifugal heat exchanger; found a geometry that >2× system COP.
Brine–CO₂ corrosion modelling, oil-field pipework (2025–26, active) — multiphase CFD with species transport.
USC approved Valve (2025) — backflow-preventer pressure-loss validation to AWWA C510 across six configurations.
EvansWerks (2023–26) — 32-month principal-engineer engagement for Product development
Patented airless tyre (2026) — coupled FEA + thermal feasibility on an adaptive airless tyre (CalculiX + Gmsh).
toronto university wind tunnel (2025) — contraction-section CFD achieving <1% velocity-profile RMS in the working section.
Credentials: Mechanical Engineering, advanced simulation focus (in progress) · BSc.Eng (Hons) Mechanical Engineering, UKZN · Aerospace Systems Research Group affiliate since 2019 · 2× granted USPTO patents in cooling-system technology.
Industries: Aerospace, Automotive, Energy, Manufacturing, Medical Devices, Consumer Products, HVAC, Electronics Cooling.
Working With Me:
Send a brief or job link → scope, a fixed or hourly quote, and a stated turnaround within one business day.
Every project ships with validated mesh, residual + Y+ + flow-uniformity plots, side-by-side configuration comparison, and a one-page executive summary.
Regular updates throughout, designs optimized for manufacturability. Overlap with US, EU, and APAC business hours.
Mechanical Engineering
ANSYS
Finite Element Analysis
Product Design
CAD
Structural Engineering
Mathematical Modeling
Physics
Hydraulic Engineering
Calculus
Computational Fluid Dynamics
CFD Analysis
OpenFOAM
HVAC System Design
MATLAB
Python
Ben N.
Mookgopong, South Africa
$75/hr
4.9
120 jobs
I help companies turn product ideas into manufacturable products ready for production.
With over 30 years of product development experience, I specialize in designing products that are not only functional and attractive, but also optimized for manufacturing processes such as injection molding, sheet metal fabrication, blow molding and die casting.
Many companies struggle to move from concept to a product that manufacturers can actually produce economically. My work focuses specifically on Design for Manufacturing (DFM) so that your product can move efficiently from prototype to mass production.
I regularly assist clients with:
• Consumer product development
• Electronic enclosure design for PCB devices
• Plastic product design for injection molding
• Bottle and container design for blow molding
• Mechanical product design for sheet metal fabrication
• Industrial equipment and vehicle accessories
My goal is simple: create product designs that manufacturers can build reliably and cost-effectively.
What you can expect when working with me
✔ A professional 3D CAD product design ready for manufacturing
✔ Designs optimized for injection molding and production
✔ Clear communication and progress updates
✔ Collaboration with your manufacturers worldwide
Experience
• Mechanical Engineering Degree (1994)
• 30 years product development experience
• Top Rated Plus freelancer on Upwork
• ~$300K earned on the platform
Previous clients include companies such as Ford, Toyota, BMW and Unilever, as well as startups and inventors developing new patented products.
If you are looking for an experienced designer who understands both product development and manufacturing, I would be happy to assist with your next project.
Mechanical Engineering
Design for Manufacturing
Finite Element Analysis
Mechanical Design
Product Design
Product Development
3D Design
3D Modeling
3D Rendering
Industrial Design
Autodesk Fusion 360
Injection Mold Design
Injection Mold
Natasja K.
Pretoria, South Africa
$7/hr
5.0
3 jobs
Hi there! I am Natasja, a Freelancer from South Africa, welcome to my page!
I have been freelancing since 2019, with a Bachelors Degree in Interior Design, and have learned a lot about business, marketing, growing my skills, and teaching others to reach for success!
When I'm not busy working, I am usually out hiking or spending time with family.
I approach all my projects with a keen eye for detail, as well as looking at the bigger picture, as I have been walking my own Design Journey for almost 10 years.
I keep myself up to date with the latest technology and advancements in the field of Design, as no one year is ever the same.
I also have the ability to adapt to various kinds of deadlines, situations and environments fairly easy, and have great project management skills.
Programs I am proficient in:
- SketchUp Pro
- VRay
- AutoCAD
- Photoshop
Projects that I have worked on:
- Photography
- Graphic Design and Illustration
- Painting with various mediums
- Mixed media art
- Education
- Business
- Coaching
- Architecture
- Carpentry
- Interior Design
- Interior Decorating
- Furniture Creation
- and a variety of other hands-on projects
Let's connect, and make your dream a reality!
SketchUp
V-Ray
Residential Design
Art & Design
Adobe Photoshop
Freestyle Drawing
Life Coaching
Business Coaching
Photography
3D Architectural Rendering
Instagram
Communications
Microsoft Office
Sculpture
Marketing
Yusuf M.
Durban, South Africa
$45/hr
5.0
6 jobs
Mechanical Design | CAD Modeling | Product Development
I help manufacturers, prototyping teams, and engineers turn ideas into production-ready designs. From concept to detailed CAD, I deliver reliable support tailored to real-world manufacturing.
With over 6 years of hands-on experience, I specialize in:
3D CAD modeling using SolidWorks and Autodesk Inventor
Manufacturing-ready 2D drawings (including GD&T, BOMs)
Assembly, enclosure, fixture, and jig design
Design for 3D printing (FDM) and STL cleanup
SolidWorks and Excel tool development for process automation
Design for manufacturing (DFM) and practical problem solving
Clients choose me for clear communication, fast turnaround, and reliable results-without the overhead of hiring full-time.
Certified SolidWorks Professional (CSWP)
Based in South Africa | Serving global clients remotely
Let’s connect to see how I can support your next project, whether it’s a quick prototype or long-term collaboration.
Mechanical Engineering
Design for Manufacturing
Engineering Design
Mechanical Design
Product Design
3D Printing
CAD
SolidWorks
Problem Solving
Machinery
Prototyping
Machine Design
Office 365
John B.
Stellenbosch, South Africa
$20/hr
5.0
27 jobs
Mechatronics Engineer Currently doing my masters part time.
Electronic Engineer at Solar MD
Experienced and Proficient In:
Fusion 360
KiCad
Arduino
STM32
ESP32
3D Printing
LTspice
Autodesk AutoCAD
Mechanical Design
3D Design
Autodesk Inventor
3D Printing
Autodesk Fusion 360
Autodesk Revit
Arduino IDE
Electronics
PCB Design
KiCad
STM32
STM32F4
ESP32
Drafting
Theo S.
Johannesburg, South Africa
$47/hr
5.0
5 jobs
With 3+ years of professional design engineering experience and over 4,000 hours of hands-on SolidWorks expertise, I help businesses transform concepts into manufacturable, high-performance solutions. Whether you’re iterating a prototype, optimizing a design for production, or reverse-engineering legacy parts, I deliver precise CAD models, actionable FEA insights, and manufacturing-ready documentation—on time and to spec.
How I Add Value to Your Project:
✔️ Mechanical Design & 3D Modeling
From sketches to detailed assemblies, I create clean, parametric SolidWorks models optimized for functionality, manufacturability, and cost-efficiency. Specializing in sheet metal, machined parts, and injection-molded assemblies.
✔️ FEA-Driven Design Validation
I don’t just run simulations—I interpret them. My stress analysis and thermal simulations identify weak points, reduce material waste, and prevent costly failures. Let’s ensure your design performs before it hits production.
✔️ 2D Drafting That Saves Time (and Headaches)
GD&T-compliant drawings, BOMs, and assembly guides tailored to your manufacturer’s requirements. I ensure seamless handoffs to machinists, fabricators, or assembly teams—no missing dimensions, no ambiguity.
✔️ Reverse Engineering for Legacy Parts & Prototypes
Lost the original CAD file? Need to modernize an old design? I rebuild accurate 3D models from photos, hand measurements, or rough sketches, preserving functionality while incorporating modern manufacturing best practices.
Why Work With Me?
✅ Manufacturing-Ready Designs: Optimized for CNC, sheet metal, and injection molding.
✅ No Surprises: Clear communication, regular updates, and revision-controlled deliverables.
✅ Trusted by Teams: Documentation that machinists and assembly teams can rely on.
Let’s Build Something Better.
Message me to discuss your project’s scope, timeline, and deliverables. I’m here to help you solve problems—not just deliver CAD files.
Mechanical Engineering
Mechanical Design
Product Development
3D Modeling
SolidWorks
Creo Parametric
Autodesk Fusion 360
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