
Joshua A
3D Product Design, Injection Mold DFM, PCB Enclosures and Jewelry CAD That Works
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Senior Product Design Engineer
Upwork • Freelance
May 2026 - Present • 6 mos
I led product design and manufacturing preparation for hardware startups and consumer product brands, taking ideas from first sketch to files a factory could build from. Most of my clients were founders with a working prototype and no clear path to production. My main work was 3D CAD design in SolidWorks, injection mold DFM reviews, and PCB enclosure design around real boards. For every project I checked wall thickness, draft angles, undercuts, gate locations and tolerances before anything went to a printer or a toolmaker. This caught problems early, when fixing them cost a few hours of CAD time instead of a steel change. Over five years I delivered more than 120 projects, including consumer electronics housings, IoT device cases, handheld tools and medical accessory parts. On several projects I ran Moldflow simulations to improve gate placement and reduce warpage and sink marks before mold release. I also prepared tool-ready CAD, 2D drawings and DFM reports that mold makers could quote and cut from without back and forth. I worked directly with clients through each stage, sent clear weekly updates, and explained technical decisions in plain English so non engineers could approve designs with confidence. I also supported first production runs by answering questions from molders and assemblers. Results I’m proud of: cut a client’s part count from 9 to 5 through redesign, and helped a hardware startup reach first shot mold approval with only minor tweaks.