Available for Projects

High-Precision Mechanical
Design & FEA Engineering

Turning complex concepts into manufacturing-ready, optimized realities. Specializing in advanced CAD modeling, structural analysis, and Design for Manufacture (DfMA).

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Daniel Tombleson
Daniel Tombleson
Mechanical Design Engineer
Specialisation Precision Systems
CAD Platform SolidWorks · ANSYS · COMSOL
Availability Open to Work
Location Isle of Wight, UK
Response Time < 24 hours

About

Engineering Solutions, Driven by Iteration

High-performance engineering requires moving seamlessly from concept to validation. I bridge the gap between initial ideas and flawless physical execution by combining robust 3D CAD modeling with rigorous finite element analysis (FEA). My approach prioritizes precision, cost-effective manufacturing, and structural integrity, ensuring your project succeeds before it ever hits the factory floor.

6+ Years
Engineering Expertise
10+
Product Iterations & Designs

Expertise

Technical skills

A broad, applied skillset built across six years of academic and professional engineering — from precision CAD to simulation, analysis, and modern AI tooling.

⚙️
CAD Development & Modeling

Complete 3D part and assembly design using SolidWorks and Fusion 360, built natively for rapid modification.

📐
Finite Element Analysis (FEA)

Advanced structural, thermal, and fluid simulations using ANSYS and COMSOL to validate performance limits.

🛠️
Design for Manufacture (DfMA)

Optimizing component geometry to minimize production costs, streamline assembly, and eliminate manufacturing defects.

🤖
Automated Workflows

Utilizing Python and custom scripting to automate complex geometric configurations and data processing.

Tools & Platforms

Adobe Suite
ANSYS
AutoCAD
COMSOL
C++
Python
SolidWorks
Onshape
OpenFOAM
FreeCAD
Fusion 360
LaTeX
Microsoft Office
SimScale
MATLAB
Adobe Suite
ANSYS
AutoCAD
COMSOL
C++
Python
SolidWorks
Onshape
OpenFOAM
FreeCAD
Fusion 360
LaTeX
Microsoft Office
SimScale
MATLAB

Work

Selected projects

A selection of engineering challenges solved — spanning simulation, hardware design, and full concept-to-prototype development.

MATLAB simulation of robotic arm — Scenario A
DissertationPythonMATLABEnergy Systems
MFC-Powered Robotic Arm — Systems Optimisation

A four-layer systems optimisation framework for a robotic arm powered entirely by Microbial Fuel Cells — covering mechanical feasibility, energy modelling, supercapacitor storage, and MFC stack design. Identified the EMAX ES08A II as optimal, achieving 2,461 theoretical actuations from 10g of apple flesh.

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Thermal Simulation — Radial Fin Array
SimulationCOMSOLThermal Analysis
Thermal Simulation — CPU Heat Sink & Radial Fin Array

COMSOL multiphysics modelling of a CPU heat sink — with and without a spreader plate — to assess and optimise heat dissipation performance. Fin geometry was systematically varied across thickness, radius, depth, and length parameters. A companion radial fin array study optimised external pipe cooling geometry through both stationary and transient thermal analysis.

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Racing Boat Keel FEA
SimulationFEAANSYS
Racing Boat Keel — Structural FEA

Full structural simulation of a marine racing keel using ANSYS, covering von Mises stress distribution, maximum bending conditions, and multi-directional impact loading. Conducted to assess structural performance, validate user safety margins, and demonstrate regulatory compliance under competitive racing conditions.

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Autonomous Specimen Collection Rover
HardwarePrototypingAutonomous Systems
Autonomous Specimen Collection Rover

A fully autonomous prototype rover designed to locate, collect, and deposit simulated specimens across a defined zone. Combines proximity sensing, Arduino control, and precision navigation to achieve positional accuracy under 5mm. The chassis was laser-cut from plywood for structural precision, with 3D-printed internals for ball channelling, hinge mechanisms, and sensor mounts.

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Deep-Sea Submersible Sensor Enclosure
Pressure-Rated Hardware Design
Deep-Sea Submersible Sensor Enclosure

Concept design and CAD development of a pressure-rated underwater CTD sensor for marine location surveying at depths up to 300m (30 bar). Engineered for low-maintenance deployment intervals, incorporating integrated data transfer systems and an optimized, cost-conscious approach to serviceability and manufacture.

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CAD Models

Precision modelling

A selection of mechanical components and assemblies — from concept geometry to production-ready 3D models.

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Model coming soon
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Services

How I can help

Three focused service offerings — built around precision engineering, rigorous analysis, and performance-led thinking.

Core Service
⎔
Engineering Design & Consultancy

End-to-end mechanical design support — from initial concept and feasibility through to detailed CAD, DFM, and production-ready documentation. I also bring engineering management experience to help navigate the commercial and supply chain realities of delivering hardware on time and on budget.

  • Mechanical design & detailed CAD
  • Concept development & feasibility
  • DFM review & supplier liaison
  • Technical documentation & reporting
  • Project & supply chain oversight
Start a Project
∿
Simulation & Analysis

Standalone simulation and analysis services to validate designs, de-risk decisions, and extract insight before committing to hardware. Results communicated clearly — not buried in technical jargon.

I work across both industry-standard and open-source simulation platforms — keeping costs lean without compromising on output quality.
  • Structural FEA (ANSYS / SimScale)
  • CFD & fluid modelling (COMSOL / OpenFOAM)
  • Thermal & multiphysics analysis
  • Design validation & test correlation
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✎
CAD Modelling

Precision 3D CAD modelling for mechanical components, assemblies, and concept designs — from initial sketches to fully constrained, production-ready models. Delivered in industry-standard formats with clean geometry and well-structured assemblies ready for manufacture or further simulation.

  • Component & assembly modelling
  • Concept design & ideation
  • DFM-informed geometry
  • Export to STEP, IGES, STL & more
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Testimonials

What clients say

Feedback from clients, collaborators, and academic supervisors.

★★★★★

"Daniel got what we were trying to do from the start. The designs he came back with were creative but practical — which is a hard balance to strike in this industry. Safety was never an afterthought, and the ergonomic improvements made a real difference to the final product. Would work with him again without hesitation."

JM
James M.
Founder, USA
★★★★★

"What stood out wasn't just the technical output — it was how the project was managed throughout. Design decisions were well reasoned and clearly communicated, and the critical requirements were always kept in focus without losing sight of the bigger picture. A genuinely considered piece of engineering work."

AT
A. Thornton
Design Lead
★★★★★

"A well-structured and clearly presented piece of analysis. The simulation results were communicated with appropriate technical rigour, and the written interpretation showed a solid understanding of the underlying mechanics. Suggestions for improvement and future work were thoughtful and grounded in the findings — not simply appended as an afterthought. A strong submission."

RC
Prof. R. Calloway
Project Supervisor, University of Southampton
★★★★★

"Good build quality and the core functionality was clearly demonstrated. There's room to develop this further — the navigation precision in particular has potential that the timeframe didn't fully allow for. That said, the integration of the mechanical and electronic systems showed solid engineering judgement, and the project achieved what was expected given the constraints."

MC
Prof. M. Clarke
Electronics & Control Engineering
Coming Soon

More client testimonials will appear here as the portfolio grows.

Coming Soon

More client testimonials will appear here as the portfolio grows.

Coming Soon

More client testimonials will appear here as the portfolio grows.

Coming Soon

More client testimonials will appear here as the portfolio grows.

Contact

Let's Build Your Next Product

Have a design challenge, a simulation requirement, or a blueprint ready for optimization? Let's map out a solution.

✉️
Email
daniel@danieltombleson.com
📍
Location
Isle of Wight, United Kingdom
🕐
Response time
Within 24 hours
💼
Availability
Open to new projects