Throughout my journey, I've had the honor of learning from and working alongside some truly outstanding individuals. Their mentorship, support, and impactful insights have been instrumental in shaping both my personal and professional development. I extend my deepest thanks to these remarkable mentors and colleagues for their invaluable contributions to my growth.

Below is a concise summary of the positions and roles I've held, presented through a Microsoft PowerBI project I've been working on. This overview highlights the range of experiences that have helped shape my professional journey.

For a comprehensive look at my background and education, please refer to the section below, which outlines the positions I've previously held and my current role. Alternatively, feel free to reach out to me for a discussion on my experiences.

Looking for a copy of my CV/resume as a download? Simply click the button below for access to download.

If you'd prefer to see a text-based version of my CV, feel free to explore it right here below.

Dale Jones
Consultant Product Design Mechanical Engineer

Summary

A highly experienced product design and mechanical engineering consultant with 18+ years of experience across various industries and a passion for using technology to make a positive impact. With a degree in automotive technology from Sheffield Hallam University and have worked with some of the industry's biggest names in the UK, Europe, and the USA.

Notable projects include: - Teledyne Defence & Space's Flexible Channeliser (FlexChan) onboard OneWeb's GEN1 $2B LEO Constellation, Selby Piper's uncrewed surface effect vehicle (USEV) awarded £254K in DASA rapid impact funding, and the Osler Origin portable lab-quality diagnostics device set to transform medical diagnostics ($85M series C). With a skill set that includes product innovation, mechanical engineering, systems engineering, computer-aided design & drafting, finite element analysis (FEA), computational fluid dynamics (CFD), data analysis and much more. For more information, please head to my LinkedIn profile.

Key Skills

Professional Experience

Senior Mechanical Engineer
PlasmaTrack - London, UK and Remote
05/22 - present

Joining as an early employee and assuming the role of Principal Engineer, I have been central to shaping the research and development trajectory of the company. My strategic leadership has been instrumental in securing a Knowledge Transfer Partnership (KTP) with the University of Edinburgh and initiating plans to establish a plasma applications lab at the University of Derby.

I pioneered the development of a semi-automated, laboratory-grade plasma test system, engineered to seamlessly integrate with the Knorr-Bremse ATLAS rig. This innovative system was crafted employing advanced production engineering methodologies, notably the Single-Minute Exchange of Die (SMED) technique, enhancing efficiency and adaptability.

In the autumn of 2022, I led the design, technical delivery, and stakeholder approval process for a high-speed plasma cleaning solution. This solution was showcased as part of the successful Network Rail Future Technologies technology demonstrator, exemplifying forward-thinking rail industry advancements.

Further expanding our technological frontier, I have developed an engineering design for a low-speed plasma cleaning solution in collaboration with SRS Road2Rail MPV.

Consultant Product Design Mechanical Engineer (Founder)
Form Lab - Leeds U.K.
01/12 - present

Achieved nine (profitable) years in business, developing ongoing relationships and value for global clients.

Total responsibility for all functions: strategy, business development, sales & marketing, design & engineering, finance & accounting, operations, human resources, legal, quality, R&D, ICT, and facilities. People management of employees, freelancers, subcontractors, suppliers, and cross‑functional teams. YOY Double‑Digit Growth (5 in 9).

Supplied product design & engineering consulting services to sectors including: -

Consultant Mechanical Engineer
Osler Diagnostics (Osler Origin Cartridge) - Remote
11/21 - 03/22

Supported the development of the Osler GEN1 Delphi cartridge for volume manufacture by injection moulding. Developed solutions to ensure DFA and DFM using Solidworks. Toolless assembly and high repeatability achieved through self‑locating features and GD&T for manufacturing control.

Contract Mechanical Engineer
PlasmaTrack (SRS RB25 Low-Speed Test Concept, Lab Test Rig & High-Speed Cleaning Solution) - Remote
08/21 - 05/22

Completed a rapid concept development of the low‑speed version of PlasmaTrack's novel track cleaning solution as featured on the BBC Click episode 'Leaves on the Line' first aired on 19th December 2020.

Developed a temporary mounting solution for the SRS RB25 Road2Rail vehicle bogie.

Also documented design, parts selection, and areas for further development in concise handover documentation. All CAD completed using Solidworks 2021 and stored for access and reuse on Solidworks PDM.

Consultant Mechanical Engineer
European Engineering & Consultancy [EECL] (RF Test Equipment Enclosure) - Remote
01/21 - 06/21

Managed the engineering and approval of a sheet metal enclosure for a new type of RF test system integrating PicoScope 9000 series scope with the customers' RF assembly comprised of low noise amplifiers (LNAs), RF switch matrix, master control PCBA and DC‑DC power supply.

Created a full manufacturing pack respecting design for manufacture (DFM) considerations.

Project‑managed sub‑contract manufacturers for prototype units and agreed on volume pricing for production parts.

Consultant Mechanical Engineer
Neutronium (Simworx ParaPod) - Remote
12/20 - 05/21

Completed eight simulation cases to support the design and development of a new virtual reality (VR) thrill ride category called ParaPod by SimWorx.

Communicated in presentation format preliminary analysis results to highlight opportunities for improvement.

Produced technical reports documenting prep to post‑analysis details to support compliance with BS EN 13814.

Consultant Mechanical Engineer
Osler Diagnostics (TPE Pinch Valve) - Remote
11/20 - 02/21

Built, developed, and solved (using Ansys mechanical) a model for a complex non‑linear simulation case of a TPE pinch valve used in medical diagnostic (in vitro) equipment.

Resolved multiple convergence issues resulting from hyper‑elastic material models (strains exceeding 300%), large displacement, contact formulation and time domain.

Contract Mechanical Engineer
Exergyn (Heat Pump) - Remote
09/20 - 11/20

Generated the 3D CAD model and costed bill of materials (BOM) of the hydraulic system for a novel shape memory alloy (SMA) heat pump from systems requirements and a hydraulic schematic.

Consultant Product Design Engineer
Selby Piper (Unmanned Surface Effect Vehicle for DASA Rapid Impact Award) - Remote
06/20 - 07/20

Converted VFX surface geometry into a 3D CAD model and product visuals to support the successful award of £254k DASA Open Call ‑ Rapid Impact 1st April 2020 to 31st March 2021 project award.

Consultant Mechanical Engineer
Teledyne Defence & Space [TDS] (Commercial Space) - Shipley, U.K. and Remote
12/19 - 08/20

Advised and delivered technical content for the VP of Business Development – Commercial Space in the fast‑paced environment of high‑value bids & tenders ranging from $3M to $500M on programmes such as Airbus LEO Vantage, Airbus TELEO, Airbus OneSat, Airbus NeoSat and MDA (Telesat Lightspeed).

Rapidly developed mechanical designs and associated technical content for the award of TELEO, OneSat & MDA contracts growing the TDS commercial space product line and adding millions in revenue. Details of these programmes and projects include: -

• Airbus DS TELEO technology demonstrator – developed full mechanical model (inc. structural and thermal analysis models) from system requirements review (SRR) up to critical design review (CDR).

• Airbus DS OneSat – developed full mechanical model (inc. structural and thermal analysis models) from system requirements review (SRR) up to critical design review (CDR) within particularly challenging mass, accommodation & thermal requirements.

• Airbus DS LEO Vantage – developed complete concept mechanical models (inc. mass budgets) of transmit (Tx) and receive (Rx) modules for a sizeable, phased array antenna (>500 elements) to support the technical bid process.

• MDA (Telesat Lightspeed) – developed mechanical concept models (inc. mass budgets) of transmit (Tx) and receive (Rx) element modules for sizeable, phased array antenna (>500 elements).

Contract Mechanical Engineer
Teledyne Defence & Space [TDS] (Flexible Channeliser for OneWeb LEO Satellite Constellation) - Shipley, U.K.
02/17 - 12/19

Developed the mechanical architecture for Teledyne Defence & Space Flexible Channeliser used onboard OneWeb LEO Satellite Constellation, awarded the Queen's Award for Enterprise two years running for the novel payload design. Details of the award, as reported by UKspace, can be found here [https://www.ukspace.org/ teledyne‑ds‑queens‑award‑second‑year/], (2020 29th April).

Also delivered an FEA campaign to support FM qualification of TDS Ka Ku waveguide filters used onboard OneWeb LEO satellite constellation.

As of 20/05/23, OneWeb launch #19 takes the total Flexible Channelisers in orbit to 634 and Ka Ku Waveguide Filters to 15216. Also conducted several shorter but equally prestigious projects, including.

FEA campaign of RF Switch Matrix for naval application. FEA studies of Threat Warning System (Phobos)

Consultant Mechanical Engineer
Neutronium (Simworx ParaDrop FEA) - Remote
10/18 - 11/18

Conducted seven simulation cases to support the design and development of a new virtual reality (VR) thrill ride called ParaDrop by SimWorx.

Communicated in presentation format preliminary analysis results to highlight opportunities for improvement. Produced technical reports documenting prep to post‑analysis details in support of compliance with BS EN 13814.

Consultant Mechanical Engineer
LDT Design (Altro Wireless Doorlock) - Remote
08/17 - 03/18

Developed two‑stage reduction gearing with manual clutch override for wireless door locks sold to the consumer electronics market under the brand Altro.

Consultant Mechanical Engineer
Saras Technology (Cavity Filter Test Jig) - Leeds, U.K.
12/16 - 01/17

Conceived, designed, and engineered for manufacturing a low‑cost ergonomic test jig for RF testing of the Saras cavity filter. Met challenging costs and timescales despite seasonal constraints.

Contract Mechanical & Automation Design Engineer
Inca Digital Printers (B1 Printer) - Cambridge, U.K.
11/16 - 02/17

Translated the industrial design concepts of machine enclosure into engineering assembly with associated manufacturing documentation concerning CE machinery directive regulations, chemical (ink) compatibility, transport, and service/ maintenance requirements. The B1 format printer is sold under the brands of Inca and Fujifilm as 'Onset M'.

Consultant Mechanical Engineer
Saras Technology (60 MHz LE Filter Test Jig) - Leeds, U.K.
06/16 - 11/16

Conceived, designed, engineered, built, tested, and supported the implementation of innovative low‑cost finishing and testing equipment for filter production volumes exceeding 20k pieces.

Consultant Product Design Mechanical Engineer
Kinetic Traction Systems - Bristol, U.K., Deeside, U.K., Chatsworth, L.A., U.S.A, and Remote
10/14 - 08/16

Managed a cross‑functional team across mechanical, electrical, and systems disciplines and worked with core suppliers to deliver a prototype 5000 SCFM high‑speed centrifugal fan for applications in the regulated wastewater treatment and processing industries, compliant with ISO 8573 and ISO 12500 quality standards.

Consultant Mechanical Engineer
Kinneir Dufort (Ultra-fast Scanning Counter Surveillance Receiver) - Remote
10/15 - 10/15

Conducted conjugate heat transfer analysis to provide analytical data supporting the development of a new enclosure design for Winklemann (UK).

Owned the project from RFQ, defined the scope of the work (SoW), and provided regular updates and final delivery of the technical report. Also documented out‑of‑spec components and highlighted recommendations for improvements to the cooling scheme.

Consultant Mechanical Engineer
Saras Technology (X-band Power Amplifier) - Leeds, U.K.
10/15 - 11/15

Delivered 2D‑3D CAD conversion and updates of X‑band PA enclosure to allow visualisation of the complete RF assembly and integration with the customer's hardware.

Consultant Mechanical Engineer
Kinneir Dufort (Vending Machine Door FEA) - Remote
07/15 - 08/15

Conducted FEA studies on three structural designs of FRP composite vending machine door concepts. This computational analysis reduced build and test costs by £125k and reduced development time by 50%. The product is used on the Lavazza Klix(R) Momentum vending machines (formerly Mars Drinks).

Consultant Mechanical Engineer
Green Frog Genovate - Remote
07/14 - 08/14

Conceived, designed, engineered, and managed the subcontract manufacture of a prototype battery storage rack for an innovative hybrid generator.

Contract Mechanical Engineer
Kinneir Dufort (Consumer Electronics Medical Device for Smoking Cessation) - Bristol, U.K.
11/13 - 08/14

Generated analytical models using FEA and CFD to demonstrate the optimum thermal control cycle for the performance and efficiency of a novel ceramic heating element coupled with a microfluidic wick.

Conducted conjugate heat transfer analysis of multiple device configurations reducing design, build & test cycles informing PK (pharmacokinetics) study for medical device regulatory approval.

Conceived, designed, and built, using ALM techniques, a test and validation system capable of quantifying the performance of the microfluidic dosing mechanism.

Performed stress analysis of mechanical assemblies, including non‑linear spring & catch components key to the UX of the device. The presentation of analysis findings contributed to customer approval and milestone payments (McNeill, part of the Johnson & Johnson group).

Also, designed and prototyped an LED light pipe in line with industrial design concepts.

Contract Mechanical Engineer
Magnomatics - Sheffield, U.K.
04/13 - 10/13

Developed a novel wing flap actuator based on pseudo‑direct drive (PDD) technology for Umbra Aerospace.

Rapidly generated and presented engineering concepts for a novel 2.5MW modular generator based on PDD technology for Garrad Hassan (now DNV GL ‑ Renewables).

Also conducted a root cause analysis of a turbo compounder high‑speed (140krpm) generator test failure for Volvo Trucks. Also, designed test equipment to test Hi‑Use EV PDD machines used on Dennis Eagle refuse trucks.

Lead Mechanical Engineer (Business Partner)
Slipstream Engineering Design (SED) - Shipley, U.K.
12/11 - 04/13

Managed all mechanical engineering requirements from request for proposal (RFP) to delivery. Developed RF test equipment for novel GaN on diamond SSPA. Created SED as a new entity and joined as a business partner. Also, led the innovation research for a new category of wireless electronics devices for the start‑up technology company Tether Ltd.

Mechanical Design Engineer
Slipstream Energy - Shipley, U.K.
11/08 - 12/11

Conceived, designed, prototyped, and tested all mechanical components for a full‑scale prototype 6kW VAWT. Designed, engineered, and built test systems to validate design and analysis predictions.

Also supported the design, analysis, testing and validation of electromechanical systems and 6m helical composite blades.

Graduate Continuous Improvement Engineer
Denso Marston - Shipley, U.K.
09/07 - 11/08

Implemented many initiatives to improve production capacity and capability at the Baildon site.

• Lean manufacturing & 5S

• Quality circles

• Key Performance Indicator (KPI) line sideboards Kaizen activities and reporting

• A new warehouse facility to improve the flow of incoming goods.

Multiple process improvements across several departments (design and production, logistics, press shop, tube welding, Nocolok & vacuum brazing, welding, assembly & test)

Several health & safety measures to improve well‑being and reduce downtime (machine and labour lost hours)

Supported the implementation of a high‑volume module assembly line using lean principles to increase capacity by ~60% with a 3ppm first‑time failure rate.

Also completed several training courses, including.

• Total Industrial Engineering (TIE) Steph 1 & Step 2 Certifications. Global 8D Training.

• Boardsley Institute Management & Leadership Development Course.

Production Engineer
BBT Thermotechnology (Bosch Buderus / Worcester Bosch) - Clay Cross, U.K.
07/05 - 08/06

Covered final assembly production engineering requirements for six production lines manufacturing a mix of oil‑fired and gas boilers.

Led the trial and successful implementation (across the business) of production and quality instructions (PQIs) to communicate production and quality standard performance metrics in a combined format based on the Bosch Production System (BPS) standardised approach. The process involved updating and creating new models and configurations using Unigraphics NX.

Supported projects to implement a step change in process improvement and technologies, including.: -

• Helping to build a case, select a vendor and conduct trials for a robotic welding cell for stainless steel secondary heat exchangers used in oil‑fired and LPG Greenstar condensing boilers.

• A super track capable of manufacturing multiple products with minimal changeover/downtime increasing output significantly whilst catering for a flexible product mix.

Education

AI and Knowledge-Based Design Optimisation in High-Value Manufacturing
University of Leeds - PhD candidate
01/19 - 07/20

Developed and trained a classification model in RStudio to identify Portuguese white wines from 12 variables. RStudio cloud project link: https://rstudio.cloud/project/370513

Validated the RAE5225 transonic aerofoil CFD model against experimental data.

Demonstrated research capabilities, critical thinking, project management, commitment to CPD and written communication by submitting an 18,000‑word transfer report including broad and complex topics including machine learning, computational fluid dynamics for aerospace, knowledge‑based optimisation, and biomimicry.

Attended many capacity building, conferences, and networking events in the fields of computer science (specifically AI, ML & data), IoT, and CFD.

Also completed several training courses, including.

• HPC Carpentry

• Research Data Management Essentials

• CIHE – Level 2 Health & Safety in the Workplace

Automotive Technology
Sheffield Hallam University - BSc (Hons) achieved a 2:1 with honours
09/02 - 09/08

Completed a 13‑month industry placement with BBT Thermotechnology UK (Worcester Bosch) with a top 5% mark awarded for placement report.

Thesis in partnership with BBT Thermotechnology, modelling the efficiency of a primary heat exchanger using CFD techniques (Gambit and Ansys Fluent).

Also competed in Formula Student (seasons 04/05 and 06/07) and served as vice president of 'Formula Materials student society.

Training Certificates

MathWorks Deep Learning Onramp 03/19 - Present
MathWorks Simulink Onramp 03/19 - Present
MathWorks MATLAB Onramp 03/19 - Present
University of Leeds Advanced Research Computing (ARC) - HPC Carpentry 02/19 - Present
University of Leeds - Research Data Management Essentials 01/19 - Present
CIHE - Level 2 Health & Safety in the Workplace 01/19 - Present
ANSYS Fluent Getting Started - Parts 1&2 12/18 - Present
ANSYS Mechanical Getting Started - Parts 1&2 11/18 - Present
Autodesk Inventor 02/17 - Present
Autodesk Fusion360 09/15 - Present
Associate Member of the Institution of Mechanical Engineers (IMechE) 05/12 - Present
Solidworks Simulation 07/09 - Present
Boardsley Institute - Management & Leadership Development 05/08 - Present
Denso Total Industrial Engineering (TIE) [Step 2] 09/08 - Present
Denso Global 8D 02/08 - Present
Denso Total Industrial Engineering (TIE) [Step 1] 11/07 - Present
Security Clearance (DV) 02/17 – N/A
Baseline Personnel Security Standard (BPSS) 02/17 – N/A

If you're curious about the details of challenges I've tackled or projects I've completed for clients, please visit the portfolio section.

To explore my ongoing professional development activities, take a look at my CPD (Continuing Professional Development) page.

If you're interested in exploring a specific facet of my experience, feel free to browse the links provided below.