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$30 USD / hour
Flag of UNITED KINGDOM
tunbridge wells, united kingdom
$30 USD / hour
It's currently 6:23 AM here
Joined September 2, 2015
0 Recommendations

Theo S.

@theosaville

 0.0 (0 reviews)
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$30 USD / hour
Flag of UNITED KINGDOM
tunbridge wells, united kingdom
$30 USD / hour
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Manufacturing & Mechanical Engineer + CAD Expert

Theo is a Manufacturing, Mechanical & Advanced Robotics Engineer, and Certified Solidworks Professional (C-WVHW5N99XH) with 7 years of experience including contracts with British police surveillance, designedbymany, Reflex Imaging, Warwick Manufacturing Group, and many more. He can provide a complete product development service, and is capable of handling every stage of the process from concept to manufacture. He can produce economical designs for all common manufacturing processes including injection moulding, sheet metal bending, CNC machining, and many more. He works freelance to fund his startup, which is bringing machine learning algorithms and artificial intelligence into CNC machining with the Entrepreneur First startup accelerator; the largest accelerator in Europe. Get in touch with Theo if you need an engineer with world-class design skills.
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Portfolio

2149752
This is a highly experimental Direct Metal Laser Melting 3D printing platform that I developed and built myself over the course of two years. Featuring a unique printing process, the machine was capable of printing 99.9% density aluminium with favourable residual stress characteristics. The process has since been patented and may be commercialised.
Experimental Metals 3D Printer
This is a highly experimental Direct Metal Laser Melting 3D printing platform that I developed and built myself over the course of two years. Featuring a unique printing process, the machine was capable of printing 99.9% density aluminium with favourable residual stress characteristics. The process has since been patented and may be commercialised.
Experimental Metals 3D Printer
This is a highly experimental Direct Metal Laser Melting 3D printing platform that I developed and built myself over the course of two years. Featuring a unique printing process, the machine was capable of printing 99.9% density aluminium with favourable residual stress characteristics. The process has since been patented and may be commercialised.
Experimental Metals 3D Printer
This is a highly experimental Direct Metal Laser Melting 3D printing platform that I developed and built myself over the course of two years. Featuring a unique printing process, the machine was capable of printing 99.9% density aluminium with favourable residual stress characteristics. The process has since been patented and may be commercialised.
Experimental Metals 3D Printer
2149707
I designed these to be injection moulded for UK company Mathsgear. Called Solids of Constant Width, they are exactly the same width no matter how you orient them, which you'd think was only true of spheres. If you put all 3 under a large book and roll them around the book will remain at a constant height from the desk. You won't be able to tell that they aren't spheres! http://mathsgear.co.uk/products/solids-of-constant-width
Injection Moulded Solids of Constant Width
2148129
Example finite element analysis and optimisation of a gear shifter fork for minimal mass using the ABAQUS FEM simulation package. I managed to reduce the mass of a high-performance gear shifter fork by ~55% through optimisation of materials and geometry.
ABAQUS FEM Mass Optimisation
2145783
This iPhone case was built and rendered for the Designed by Many product design house, which specializes in premium apple accessories.
TUFF iPhone Case
This iPhone case was built and rendered for the Designed by Many product design house, which specializes in premium apple accessories.
TUFF iPhone Case
2145773
I was chief engineer on the Warwick University Human Powered Submarine project. This involved the development and manufacture of a racing submarine to compete at the International Submarine Races, held at the Naval Surface Warfare Centre in Washington DC. The submarine comprised more than 700 components, at a value of ~$250,000, and required a year to design and manufacture. The submarine was awarded the prize for Most Innovative Submarine, for extensive use of 3D printed components, an advanced hybrid composite shell, modularised design and flat-pack ability for transport.
Human Powered Submarine
I was chief engineer on the Warwick University Human Powered Submarine project. This involved the development and manufacture of a racing submarine to compete at the International Submarine Races, held at the Naval Surface Warfare Centre in Washington DC. The submarine comprised more than 700 components, at a value of ~$250,000, and required a year to design and manufacture. The submarine was awarded the prize for Most Innovative Submarine, for extensive use of 3D printed components, an advanced hybrid composite shell, modularised design and flat-pack ability for transport.
Human Powered Submarine
I was chief engineer on the Warwick University Human Powered Submarine project. This involved the development and manufacture of a racing submarine to compete at the International Submarine Races, held at the Naval Surface Warfare Centre in Washington DC. The submarine comprised more than 700 components, at a value of ~$250,000, and required a year to design and manufacture. The submarine was awarded the prize for Most Innovative Submarine, for extensive use of 3D printed components, an advanced hybrid composite shell, modularised design and flat-pack ability for transport.
Human Powered Submarine
I was chief engineer on the Warwick University Human Powered Submarine project. This involved the development and manufacture of a racing submarine to compete at the International Submarine Races, held at the Naval Surface Warfare Centre in Washington DC. The submarine comprised more than 700 components, at a value of ~$250,000, and required a year to design and manufacture. The submarine was awarded the prize for Most Innovative Submarine, for extensive use of 3D printed components, an advanced hybrid composite shell, modularised design and flat-pack ability for transport.
Human Powered Submarine
I was chief engineer on the Warwick University Human Powered Submarine project. This involved the development and manufacture of a racing submarine to compete at the International Submarine Races, held at the Naval Surface Warfare Centre in Washington DC. The submarine comprised more than 700 components, at a value of ~$250,000, and required a year to design and manufacture. The submarine was awarded the prize for Most Innovative Submarine, for extensive use of 3D printed components, an advanced hybrid composite shell, modularised design and flat-pack ability for transport.
Human Powered Submarine
2145749
I was contracted to develop the chassis and casing for an ultra-accurate, ultra-precise laser rangefinder for use in radiotherapy equipment. Fulfilling the design specification required the use of exotic materials to counter vibration and thermal expansion.
Radiotherapy Specific Ultra-Precision Laser Rangefinder
2149752
This is a highly experimental Direct Metal Laser Melting 3D printing platform that I developed and built myself over the course of two years. Featuring a unique printing process, the machine was capable of printing 99.9% density aluminium with favourable residual stress characteristics. The process has since been patented and may be commercialised.
Experimental Metals 3D Printer
This is a highly experimental Direct Metal Laser Melting 3D printing platform that I developed and built myself over the course of two years. Featuring a unique printing process, the machine was capable of printing 99.9% density aluminium with favourable residual stress characteristics. The process has since been patented and may be commercialised.
Experimental Metals 3D Printer
This is a highly experimental Direct Metal Laser Melting 3D printing platform that I developed and built myself over the course of two years. Featuring a unique printing process, the machine was capable of printing 99.9% density aluminium with favourable residual stress characteristics. The process has since been patented and may be commercialised.
Experimental Metals 3D Printer
This is a highly experimental Direct Metal Laser Melting 3D printing platform that I developed and built myself over the course of two years. Featuring a unique printing process, the machine was capable of printing 99.9% density aluminium with favourable residual stress characteristics. The process has since been patented and may be commercialised.
Experimental Metals 3D Printer
2149707
I designed these to be injection moulded for UK company Mathsgear. Called Solids of Constant Width, they are exactly the same width no matter how you orient them, which you'd think was only true of spheres. If you put all 3 under a large book and roll them around the book will remain at a constant height from the desk. You won't be able to tell that they aren't spheres! http://mathsgear.co.uk/products/solids-of-constant-width
Injection Moulded Solids of Constant Width
2148129
Example finite element analysis and optimisation of a gear shifter fork for minimal mass using the ABAQUS FEM simulation package. I managed to reduce the mass of a high-performance gear shifter fork by ~55% through optimisation of materials and geometry.
ABAQUS FEM Mass Optimisation
2145783
This iPhone case was built and rendered for the Designed by Many product design house, which specializes in premium apple accessories.
TUFF iPhone Case
This iPhone case was built and rendered for the Designed by Many product design house, which specializes in premium apple accessories.
TUFF iPhone Case
2145773
I was chief engineer on the Warwick University Human Powered Submarine project. This involved the development and manufacture of a racing submarine to compete at the International Submarine Races, held at the Naval Surface Warfare Centre in Washington DC. The submarine comprised more than 700 components, at a value of ~$250,000, and required a year to design and manufacture. The submarine was awarded the prize for Most Innovative Submarine, for extensive use of 3D printed components, an advanced hybrid composite shell, modularised design and flat-pack ability for transport.
Human Powered Submarine
I was chief engineer on the Warwick University Human Powered Submarine project. This involved the development and manufacture of a racing submarine to compete at the International Submarine Races, held at the Naval Surface Warfare Centre in Washington DC. The submarine comprised more than 700 components, at a value of ~$250,000, and required a year to design and manufacture. The submarine was awarded the prize for Most Innovative Submarine, for extensive use of 3D printed components, an advanced hybrid composite shell, modularised design and flat-pack ability for transport.
Human Powered Submarine
I was chief engineer on the Warwick University Human Powered Submarine project. This involved the development and manufacture of a racing submarine to compete at the International Submarine Races, held at the Naval Surface Warfare Centre in Washington DC. The submarine comprised more than 700 components, at a value of ~$250,000, and required a year to design and manufacture. The submarine was awarded the prize for Most Innovative Submarine, for extensive use of 3D printed components, an advanced hybrid composite shell, modularised design and flat-pack ability for transport.
Human Powered Submarine
I was chief engineer on the Warwick University Human Powered Submarine project. This involved the development and manufacture of a racing submarine to compete at the International Submarine Races, held at the Naval Surface Warfare Centre in Washington DC. The submarine comprised more than 700 components, at a value of ~$250,000, and required a year to design and manufacture. The submarine was awarded the prize for Most Innovative Submarine, for extensive use of 3D printed components, an advanced hybrid composite shell, modularised design and flat-pack ability for transport.
Human Powered Submarine
I was chief engineer on the Warwick University Human Powered Submarine project. This involved the development and manufacture of a racing submarine to compete at the International Submarine Races, held at the Naval Surface Warfare Centre in Washington DC. The submarine comprised more than 700 components, at a value of ~$250,000, and required a year to design and manufacture. The submarine was awarded the prize for Most Innovative Submarine, for extensive use of 3D printed components, an advanced hybrid composite shell, modularised design and flat-pack ability for transport.
Human Powered Submarine
2145749
I was contracted to develop the chassis and casing for an ultra-accurate, ultra-precise laser rangefinder for use in radiotherapy equipment. Fulfilling the design specification required the use of exotic materials to counter vibration and thermal expansion.
Radiotherapy Specific Ultra-Precision Laser Rangefinder

Reviews

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Experience

Advanced Engineering Research

Warwick Manufacturing Group
Jan 2014 - Present
At WMG I primarily act as an engineering consultant, through which I am involved in a wide variety of projects such as factory optimisation, metal additive manufacture research, and development of bespoke surveillance solutions. Many tasks involve solving problems with novel designs that can only be achieved through 3D printing.

Freelance Engineer

Upwork
Jan 2014 - Aug 2015 (1 year, 7 months)
I previously worked on the Upwork and Elance freelancing platforms, taking on a variety of projects. I was a top-rated freelancer, with 5* feedback. My profile can be found here: https://www.upwork.com/o/profiles/users/_~017d143ddb5f993c72/

Weapons Development

Atkins Defence
Apr 2013 - Sep 2013 (5 months, 1 day)
Over summer 2013 I worked in the defence division of WS Atkins, primarily on projects involving systems engineering, market assessments, and the Bulldog armoured fighting vehicle.

Education

Manufacturing & Mechanical Engineering with Advanced Robotics (Masters)

University of Warwick, United Kingdom 2011 - 2015
(4 years)

Qualifications

Duolingo Proficiency Exam in English

Duolingo
2015
Score: 10.0/10.0 - Expert. Can understand virtually anything heard or read, even intellectually demanding material such as an academic lecture or a book on philosophy. Can use the language fluently and spontaneously in a way that can even be more advanced than an average native speaker. https://certs.duolingo.com/rv6c45zm

Certified Solidworks Professional

DS Solidworks Corporation
2013
A Certified SOLIDWORKS Professional is an individual who has successfully passed the SOLIDWORKS advanced skills examination. Each CSWP has proven their ability to design and analyze parametric parts and moveable assemblies using a variety of complex features in SOLIDWORKS software. Certification number: C-WVHW5N99XH

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Certifications

us_eng_3.png US English 3 85%

Top Skills

CAD/CAM
3D Rendering
Solidworks
Mechanical Engineering
Manufacturing Design

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