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Mechanical Design Engineer, P.E.

Engineering precision into every moving part.

I design, simulate, and validate mechanical systems — from concept sketch to manufactured part — for automotive, robotics, and industrial automation clients.

9+Years in industry
40+Products shipped
6Patents filed
3FAA / ISO audits passed
Marcus Hale, Mechanical Design Engineer, P.E.
MARCUS HALEMECHANICAL DESIGN ENGINEER
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SolidWorksCATIA V5Fusion 360AutoCADANSYS MechanicalANSYS FluentMATLABKeyShotSolidWorksCATIA V5Fusion 360AutoCADANSYS MechanicalANSYS FluentMATLABKeyShot
01About

From first sketch to final spec.

Core focus

  • Structural design & FEA validation
  • DFM / DFA for high-volume manufacturing
  • GD&T and tolerance stack-up analysis
  • Cross-functional work with electrical & firmware teams

I'm a Mechanical Design Engineer with nine years of experience taking products from a napkin sketch to a validated, manufactured assembly. My background spans automotive structures, robotic actuation, and precision sheet-metal enclosures — wherever tolerances are tight and failure isn't an option.

Good mechanical design is invisible until it isn't — a bracket that never cracks, a hinge that never binds, a chassis that passes every drop test on the first try. I lean on first-principles analysis and simulation before a single prototype gets cut, because every revision costs time the schedule doesn't have.

Detroit, MIOpen to new opportunities
02Selected Work

Hardware that ships and holds tolerance.

01CASE STUDY

Lightweight EV Battery Enclosure

Structural redesign of a battery enclosure for an electric delivery van, cutting mass while meeting UN38.3 crush and IP67 sealing requirements.

SolidWorksANSYS MechanicalAluminum 6061DFM
  • 18% mass reduction vs. prior generation
  • Passed crush + thermal cycling on first prototype run
  • Tooling cost reduced by consolidating 14 parts into 6
02CASE STUDY

6-Axis Robotic Gripper

Precision end-effector for a pick-and-place robot handling fragile electronics, with a compliant mechanism replacing pneumatic actuation.

Fusion 360MATLAB3D Printing (SLS)Compliant Mechanisms
  • Cycle time improved by 22%
  • Zero pneumatic lines — lower maintenance overhead
  • Grip force repeatable within ±0.3 N across 50k cycles
03CASE STUDY

HVAC Duct Energy Optimization

CFD-driven redesign of commercial rooftop HVAC ductwork to reduce static pressure loss and fan energy draw across a 12-building portfolio.

ANSYS FluentAutoCAD MEPSheet MetalEnergy Modeling
  • 14% reduction in fan energy consumption
  • Static pressure loss cut by 1.1 in. w.g.
  • ROI on retrofit under 18 months
04CASE STUDY

Precision CNC Fixture System

Modular 5-axis machining fixture for a family of turbine housings, replacing single-use tooling with a reconfigurable clamping platform.

CATIA V5GD&TTolerance Stack-UpHardened Steel
  • Fixture changeover time down from 90 to 12 minutes
  • Positional repeatability held to ±0.02 mm
  • Single fixture family covers 9 part variants
03Experience

Nine years on the production floor and in the FEA solver.

Senior Mechanical Design Engineer · Ironclad Motion Systems

2021 — Present

Lead structural and mechanism design for robotic automation products. Own FEA validation, DFM reviews, and supplier tooling sign-off from concept through production.

FEA ValidationDFM LeadershipSupplier Tooling

Mechanical Engineer II · Vantage Automotive Group

2018 — 2021

Designed structural battery and chassis components for EV platforms. Ran crash, thermal, and fatigue simulations and coordinated prototype builds with three contract manufacturers.

Crash & Fatigue CAEEV StructuresPrototype Builds

Mechanical Engineer · Halsted Industrial Co.

2016 — 2018

Designed sheet-metal enclosures and HVAC ductwork for commercial mechanical systems. Produced fabrication drawings and ran CFD studies for airflow optimization.

Sheet Metal DesignCFD AnalysisFabrication Drawings
04Skills

Tools I trust under deadline pressure.

Design & CAD

SolidWorks95%
CATIA V580%
Fusion 36088%
AutoCAD85%

Simulation & Analysis

ANSYS Mechanical90%
ANSYS Fluent (CFD)75%
MATLAB78%
GD&T / Tolerance Stack-Up92%

Manufacturing

DFM / DFA90%
CNC Machining82%
Sheet Metal Fabrication86%
Injection Molding70%

Tools & Process

PDM / PLM (SolidWorks PDM)84%
Six Sigma (Green Belt)76%
Project Coordination80%
05Credentials

Licensed, certified, and patented.

Professional Engineer (P.E.)

Michigan State Board of Engineering

2022

Six Sigma Green Belt

ASQ

2020

GD&T Professional Certification

ASME Y14.5

2019

US Patent — Compliant Robotic Gripper Mechanism

USPTO

2023

06Get In Touch

Have a part that needs designing right?

Whether it's a structural review, a DFM pass before tooling, or a full design from spec — I'd like to hear about it.