Mechanical Engineer

Hi, I'm Danny.
I build things that work.

Mechanical engineer passionate about design, simulation, and the intersection of hardware and software. I document what I build and what I learn.

A bit about me

Engineer by training, problem-solver by nature.

I'm a Mechanical Engineer with a focus on design, structural analysis, and prototyping. I enjoy working on projects that require both analytical rigor and creative thinking — from CAD models to physical builds.

Beyond the lab and workshop, I explore programming, automation, and how software tools can enhance engineering workflows. I believe great engineers never stop learning — so I write about everything I figure out.

Currently open to collaborations, internships, and interesting engineering challenges.

10+
Projects Completed
3+
Years of Experience
5+
Tools & Software
Things to Learn
Things I've built

A selection of engineering projects — design, fabrication, and analysis.

Suspension Design Optimization

Analyzed and optimized a double-wishbone suspension geometry for a lightweight EV prototype using FEA and dynamic simulation. Reduced component stress by 22% while cutting weight.

FEA CAD SolidWorks ANSYS
GitHub

Heat Exchanger CFD Study

Designed and simulated a shell-and-tube heat exchanger for a HVAC application. Used computational fluid dynamics to evaluate flow distribution and thermal efficiency under varying load conditions.

CFD Thermal ANSYS Fluent Python
GitHub

3D-Printed Robotic Gripper

Designed an underactuated compliant gripper with 3 fingers capable of grasping irregular objects. Fabricated via FDM printing with TPU flexures. Integrated with Arduino for control.

Robotics Fabrication Fusion 360 Arduino
GitHub

Structural Load Analysis Tool

Built a Python script to automate cross-section property calculations and beam deflection analysis for standard structural profiles. Outputs plots and CSV reports for quick design review.

Automation Structures Python Matplotlib
GitHub
Work in progress

Live projects I'm actively building or researching.

Active

DIY CNC Mill Build

Designing and assembling a small-format CNC milling machine from scratch — mechanical, electronics, and firmware.

55% complete
Active

Personal Website (GitHub Pages)

Building and iterating this portfolio site — you're looking at it.

80% complete
Research

FEA with Python (FEniCSx)

Learning open-source finite element analysis using FEniCSx to move beyond proprietary tools.

30% complete
Tech & tools

My engineering toolkit — software, methods, and languages.

CAD / Modelling

SolidWorks Fusion 360 AutoCAD Onshape

Simulation

ANSYS ANSYS Fluent MATLAB Simulink

Programming

Python MATLAB C++ (Arduino) Bash

Fabrication

FDM 3D Printing Machining Welding (MIG) Laser Cutting

Analysis

FEA CFD GD&T DFM

Dev Tools

Git GitHub VS Code Jupyter
Notes & write-ups

Things I figured out — documented so I (and maybe you) don't forget.

2025 / 04

Why your FEA mesh is probably wrong

Lessons from mesh convergence studies and what "good enough" actually means in practice.

2025 / 02

Automating boring engineering tasks with Python

How I saved hours of manual spreadsheet work using pandas and matplotlib for load reporting.

2024 / 11

Understanding tolerances: GD&T for real parts

A practical breakdown of geometric dimensioning and why it matters when you hand off drawings to a machinist.

2024 / 08

What I learned building a 3D printer from scratch

CoreXY kinematics, PID tuning, and the five things I'd do differently the second time around.

2024 / 05

Getting started with CFD — a beginner's honest guide

What the tutorials don't tell you about setting up boundary conditions and interpreting residuals.

Let's connect

Whether it's a project, collaboration, or just engineering talk — my inbox is open.