Mechanical Design Engineer
Brahim
Khaloua
SolidWorks Expert & DFM Specialist with 4+ years delivering precision-engineered solutions — from complex piping systems and sheet metal assemblies to FEA thermal analysis and CFD fluid simulations.
View Portfolio4+
Years of Experience
150+
Projects Delivered
50+
Students Mentored
CSWP
SolidWorks Certified
Portfolio
Engineering Projects
Each project documented using the STAR methodology — Situation, Task, Action, Result.
01
Piping & Industrial Routing System
Multi-Pump Skid Assembly — Full BOM & GD&T Manufacturing Package
SolidWorks RoutingGD&TBOMASME B16.34Isometric Drawings
35+
BOM Line Items
4
Pump Stations
0
Design Interferences
ASME
Compliance
Situation
An industrial fluid-handling client required a fully routed multi-pump piping assembly for four centrifugal pump stations, compliant with ASME B16.34 valve standards and ASME B36.10M piping specifications, deliverable as a complete manufacturing package.
Task
Design a complete 3D piping assembly in SolidWorks Routing incorporating 5-inch Schedule 40 pipes, globe valves, slip-on weld flanges, welding neck flanges, 90° LR elbows, and straight tees — plus a fully dimensioned 2D manufacturing drawing package with a structured 35-item BOM.
Action
Modelled all piping runs using SolidWorks Routing with ASME-compliant fittings. Configured route assemblies for four parallel pump branches with shared inlet and discharge headers. Applied GD&T callouts (position, perpendicularity, flatness) on flange interfaces. Generated orthographic and isometric views with complete BOM. Validated all connections via interference detection.
Result
Delivered an interference-free 3D assembly, isometric drawing, and 35-item BOM approved for fabrication. Routing methodology documented as a reusable template, reducing future setup time by ~30%.
Multi-Pump Skid — SolidWorks Rendered View
SolidWorks Routing Assembly Tree
3D Piping Route Model
Technical Drawing with Dimensions & BOM Table
Piping Route Detail View
02
Sheet Metal Design — Off-Road Front Bumper
Automotive DFM — Base-Flange / Edge-Flange / Flat-Pattern Workflow
SolidWorks Sheet MetalBase-FlangeEdge-FlangeDXF ExportDFMSolidWorks Visualize
4
SM Panels
22%
Bend Ops Reduced
3mm
ASTM A36 Steel
DXF
CNC-Ready Output
Situation
An automotive aftermarket client needed a custom heavy-duty front bumper for an off-road vehicle requiring aggressive styling, structural integrity under impact, and full compatibility with CNC plasma cutting and brake-press bending — within tight budget and lead time.
Task
Model a multi-panel welded sheet metal bumper in SolidWorks Sheet Metal, produce accurate flat-pattern DXF files for CNC plasma cutting, and calibrate all bend allowances and K-factors for 3mm mild steel stock.
Action
Built geometry using Base-Flange and Edge-Flange workflow. Configured K-factor bend allowances for 3mm ASTM A36 steel. Applied Bend Relief and Closed Corners to prevent tearing. Integrated cut-outs for winch fairlead, LED light bar, and tow hooks. Exported flat-pattern DXF and cleaned via DXF/DWG Cleanup. Applied DFM: minimised bend count, avoided tight-radius bends, standardised hole sizes.
Result
Delivered 4 validated flat-pattern panels ready for CNC plasma cutting. DFM confirmed 22% reduction in bend operations. Rendered visualisation used directly in the client's marketing catalogue.
Off-Road Bumper — 3D SolidWorks Render
Sheet Metal Flat-Pattern View
DXF/DWG Cleanup — CNC-Ready Output
03
Thermal FEA — Engine Cylinder Head
ANSYS Mechanical R16.2 — Steady-State Thermal — Directional Heat Flux (X-Axis)
ANSYS Mechanical R16.2Steady-State ThermalFEAHeat Flux AnalysisSolidWorks Geometry Prep
2×10⁷
Max Flux W/m²
4
Cylinders
FEA
Analysis Method
R16.2
ANSYS Version
Situation
A steady-state thermal FEA study was required to evaluate the thermal performance of a 4-cylinder engine cylinder head under combustion loads. Understanding directional heat flux patterns was critical to identifying thermal fatigue risk zones and guiding coolant passage design.
Task
Execute a steady-state thermal FEA on the cylinder head to map Directional Heat Flux (W/m²) along the X-axis, identify peak thermal gradients, and assess symmetry of heat distribution across all four combustion chambers.
Action
Prepared geometry in SolidWorks and imported into ANSYS Mechanical. Defined convective heat transfer coefficients on coolant passages and combustion face heat loads. Meshed with tetrahedral elements refined at ports and valve seats. Post-processed Directional Heat Flux — maximum 2.00×10⁷ W/m² at combustion deck, minimum -2.82×10⁷ W/m² at coolant interfaces.
Result
Identified critical hotspots between exhaust valves. Confirmed symmetry across all four bores. Results informed coolant passage redesign recommendations, demonstrating FEA-guided DFM reducing physical prototyping iterations.
Directional Heat Flux — Isometric View (ANSYS R16.2)
Heat Flux Distribution — 4-Cylinder Top View
04
CFD Fluid Simulation — Shell & Tube Heat Exchanger
SolidWorks Flow Simulation — Flow Trajectories & Temperature Distribution Analysis
SolidWorks Flow SimulationCFDHeat TransferFlow TrajectoriesSolidWorks Visualize
80→10°C
Temperature Range
230
Solver Iterations
2
Fluid Circuits
CFD
Simulation Type
Situation
A thermal systems client required CFD validation of a shell-and-tube heat exchanger before fabrication. The design involved two fluid circuits — hot process fluid on shell side, cooler service fluid through tube bundle — needing confirmation of thermal uniformity and absence of recirculation dead zones.
Task
Conduct a CFD analysis to model internal flow trajectories for both fluid streams, map temperature distribution at steady-state convergence, and identify thermal short-circuiting or stagnation zones.
Action
Set up the internal analysis domain with shell-side and tube-side fluid subdomains. Applied inlet velocity and temperature BCs. Ran simulation to convergence at iteration 230. Generated Flow Trajectory plots colour-mapped to fluid temperature (10–80°C). Analysed mixing patterns, gradients, and stratification near inlet nozzles.
Result
Confirmed effective counter-flow heat exchange — no dead zones or recirculation detected. Hot-side temperatures progressively cooled along shell length. Results validated design for fabrication and were incorporated into the client's engineering report.
Flow Trajectories — Cut Section View
Temperature Distribution — External View
SolidWorks Flow Simulation Assembly
05
Advanced Assembly Design & Mechatronics
Hydraulic Floor Jack Reverse Engineering + Reflex Testing Machine — Full Cycle
SolidWorks AssemblyWeldmentsSolidWorks VisualizeKeyShotArduino C/C++Fabrication
<10ms
Reaction Resolution
100%
Self-Fabricated
Arduino
Control Platform
Full Cycle
Concept→Prototype
Situation
Two parallel projects: (1) Reverse-engineering and 3D modelling of a hydraulic floor jack for a fully-constrained SolidWorks assembly and photorealistic render; (2) A self-initiated mechatronics project — a reflex testing game machine built entirely from scratch.
Task
Floor Jack: fully-constrained SolidWorks assembly with correct mate relationships and photorealistic KeyShot render. Reflex Machine: design weldment frame, fabricate it, integrate LED/button electronics, and program the Arduino microcontroller for millisecond-precision timing.
Action
Floor Jack: Modelled all sub-components (frame, saddle, pump, scissor linkage, wheels, fasteners) with concentric, parallel, and width mates. Applied realistic materials and rendered in SolidWorks Visualize. Reflex Machine: Designed 40×40mm hollow-section steel weldment frame in SolidWorks, performed all MIG welding and fabrication, integrated LED targets, push-buttons, LCD display, programmed timing in Arduino C/C++ with interrupt-driven detection.
Result
Floor jack: fully constrained assembly, 0 over-defined mates, photorealistic renders delivered. Reflex machine: operational prototype with <10ms resolution, tested with 50+ users without failure — validating competency across all product development phases.
Hydraulic Floor Jack — Full Assembly Render
Floor Jack — Detail Render (Side View)
Floor Jack — Front Elevation Render
Precision Mechanical Component — Red Bracket (KeyShot Render)
B1
Public Monument — 2m Diameter Modular Ring Structure
Sheet Metal Assembly — High-Tolerance Segmented Ring with Arabic Calligraphy Engraving
SolidWorks AssemblySheet MetalLocalCirPatternSolidWorks Visualize
Led the advanced Sheet Metal Assembly modelling for a 2-metre diameter modular ring structure for a public monument. The project required high-tolerance mating surfaces across 13+ identical circular segments managed via LocalCirPattern1 in SolidWorks Assembly. Each panel features applied decorative Arabic calligraphy motifs engraved as extruded cuts. A photorealistic environment composite was produced in SolidWorks Visualize placing the monument in a real urban waterfront setting for stakeholder presentation. The project resulted in successful on-site physical erection.
Ring Assembly — SolidWorks Model (13 Segments)
Detail View — Arabic Calligraphy Engraved Panels
B2
Agricultural Irrigation Distribution Tray
Product Design — Radial Rib Drip Irrigation Component — Field Tested in Vineyard
SolidWorks Part DesignParametric FeaturesSolidWorks VisualizePrototyping
Designed an agricultural irrigation water distribution tray featuring a radial rib pattern emanating from a central drip emitter mount — providing structural rigidity and optimal water distribution geometry. All ribs were parametrically modelled using SolidWorks pattern features. The design was physically prototyped and field-tested in a real vineyard environment, confirming performance, UV resistance, and mechanical durability under outdoor conditions. This exemplifies the full product development cycle: CAD design → render → prototype → field validation.
Irrigation Tray — 3D Render (Radial Rib Design)
Field Installation — Real Vineyard Deployment
Expertise
Technical Proficiency
Comprehensive skill set spanning design, simulation, manufacturing, and programming.
CAD & Modelling
SolidWorks (Expert — CSWP) · CATIA V5 · AutoCAD Mechanical · Autodesk Inventor · Fusion 360
FEA & CFD Simulation
ANSYS Mechanical (Thermal/Static/Dynamic/Fatigue) · SolidWorks Flow Simulation · Vibration Analysis · Stress & Fatigue
Sheet Metal & Weldments
Base-Flange · Edge-Flange · Flat-Pattern · Bend Relief · Weldment Profiles · Structural Members · DFM Optimisation
Piping & Routing
SolidWorks Routing · ASME B16.34 / B36.10M · GD&T · BOM Management · Isometric Drawings · Interference Detection
Manufacturing & DFM
CNC Programming (G-Code) · SolidCAM · Welding (MIG/TIG) · Prototyping · Reverse Engineering · Material Selection · QC
Rendering & Visualisation
KeyShot · SolidWorks Visualize · Photorealistic Product Renders · Marketing Presentations · Environment Compositing
Programming & Tools
MATLAB · Python · Arduino (C/C++) · Microsoft Office · Technical Documentation · BOM & Scheduling
Standards & Analysis
GD&T (ASME Y14.5) · Failure Analysis · Thermodynamics · Fluid Mechanics · Heat Transfer · Strength of Materials
Attributes
Soft Skills
Problem-Solving
Root-cause analysis & DFM-driven engineering solutions
Project Management
BOM, scheduling, cost estimation & milestone delivery
Client Communication
Clear technical reporting for international clients
Mentorship
50+ students trained in advanced SolidWorks & CAD
Continuous Learning
Self-driven upskilling & professional certification
Background
Education & Certifications
Education
Master's in Mechanical Engineering
University of Aïn Témouchent, Algeria
Sep 2015 – Sep 2020
Focus: Product Design, Simulation & Manufacturing Processes
Certification
Certified SolidWorks Professional (CSWP)
Advanced Professional Certification
Languages
Arabic (Native) · English (Excellent)
French (Intermediate) · Spanish (Intermediate)
French (Intermediate) · Spanish (Intermediate)