Mohamed Refaat

Operations Manager • Product Analyst • Product Designer • Cairo, Cairo Governorate, EG

Product Development

Industrial Engineering

Design

3D Modeling

Mechanical Engineering

Mechanical Design

Available for hire fromNegotiable

Contracts

Technical Consultant @ Machines & Aluminium Center | Mechanical Design, HPDC, Plastic Injection, Sheet Metal, Jigs & fixtures, DFM, R&D

As an Industrial and Mechanical Design Engineer, I am driven by a passion for tackling new challenges and exploring innovative solutions. With a solid foundation of experience, I am equipped to address complex problems through a blend of practical expertise and a forward-thinking approach. I am constantly seeking opportunities to embrace emerging technologies and methodologies, eager to contribute to the advancement of the industry. I thrive in dynamic environments that demand creativity, precision, and strategic problem- solving, and I am enthusiastic about leveraging my skills to drive impactful results in the ever-evolving landscape of engineering and design.

Projects

Waiting Chairs

Waiting Chairs — Reverse Engineering, Cost Optimization & Tooling I reverse engineered an existing waiting chair, optimizing its design for cost reduction, durability, and manufacturing efficiency. Delivered precise 3D models, manufacturing drawings, and complete tooling (jigs, fixtures, sheet metal forming tools). Supervised toolmaking and production, ensuring smooth implementation. The result: reduced costs, scalable tooling, and a market-ready product.See More

Arm Rest

Arm Rest — Reverse Engineering, Cost Optimization & Tooling I reverse engineered an arm rest assembly and redesigned it for cost savings, manufacturability, and ergonomic performance. Delivered CAD models, refined design, and complete tooling (plastic injection molds and sheet metal tools). Produced full technical documentation, supervised toolmaking, and supported production until market launch. Result: cost-efficient, scalable, and market-ready solution.See More

Chair Mechanism

Chair Mechanism — Reverse Engineering, Cost Optimization & Tooling I reverse engineered an existing chair mechanism and optimized it for cost, manufacturability, and performance. Delivered precise CAD models, streamlined design, and full tooling (sheet metal jigs, forming tools, and plastic injection molds). Produced detailed drawings, supervised toolmaking, and guided production until successful launch. Result: cost savings, scalable tooling, and a market-ready mechanism.See More

Dish Cover

Dish Cover — Reverse Engineering & Plastic Injection Molds I reverse engineered two dish cover products, modified designs to meet customer requirements, and developed dedicated injection molds. Managed complete in-house manufacturing with my team, from machining to finishing, followed by trials and validation. Delivered two production-ready molds ensuring dimensional accuracy, functionality, and scalable manufacturing.See More

Watch Body

Watch Body — DFM & HPDC + Plastic Injection Molds I led the full development of three molds for a watch body: two hot-chamber HPDC molds for metal parts and one plastic injection mold. Starting with reverse engineering, I optimized designs for manufacturability, tailored gating/cooling, and ensured part quality. All molds were fabricated in-house, trialed, and validated, delivering a robust, cost-effective, production-ready solution for both metal and polymer components.See More

Oven Flame Spreader Die Casting Mold (RFM)

This die casting mold is specifically designed for an Oven Flame Spreader, complete with a full set of components. It goes beyond a simple 3D model, offering comprehensive detailed drawings, a bill of materials, manufacturing guidelines, and production notes. Part of the RFM (Ready for Manufacturing) series, this mold is meticulously prepared for efficient production, ensuring precision and reliability in manufacturing. Ideal for manufacturers looking for a complete, ready-to-use solution for oven components.See More

Test Tube Plastic Injection Molds (RFM)

This plastic injection mold set is engineered specifically for Test Tube, consisting of two separate molds: one for the test tube body and another for the test tube cover. Both molds utilize a 3-plate mold design for efficient part separation and enhanced productivity. The set comes as a full package, including 3D models, detailed technical drawings, a bill of materials, as well as precise manufacturing guidelines and production notes. As part of the RFM (Ready for Manufacturing) series, these molds are optimized for high-volume production, ensuring accuracy, quality, and cost-effectiveness.See More

Washing Powder Scoop - RFM

This 3D model features a single-cavity plastic injection mold for a Washing Powder Scoop. Designed with a hot runner system and close nozzle-part coupling for efficient heating, it includes a robust stripper plate for reliable ejection. Delivered as part of the RFM (Ready for Manufacturing) series, the package includes 3D files, technical drawings, BOM, and production notes—ideal for cost-effective, medium- to high-volume manufacturing.See More

3-Way Adaptor Plastic Injection Mold - RFM

This plastic injection mold set is designed for a 3-way adaptor, featuring a dual-cavity layout with a sliding system for complex geometry. Part of the RFM (Ready for Manufacturing) series, it includes 3D models, technical drawings, a bill of materials, and production guidelines. Optimized for high-volume manufacturing, the mold ensures accuracy, efficient ejection, and consistent performance—ideal for manufacturers seeking a reliable, ready-to-use tooling solution.See More

Strain Relief Cover

Strain Relief Cover — DFM & Plastic Injection Mold I reverse engineered a strain relief cover, optimized its design with DFM principles (uniform walls, draft, ribs), and developed a complete injection mold. Fabricated the mold in-house with my team, ran trials, and validated parts for accuracy and reliability. Delivered a robust, production-ready tool ensuring consistent, scalable manufacturing.See More

Ice Cream Box

Ice Cream Box — DFM & Plastic Injection Molds I developed two molds for an ice cream box and its cover, starting with reverse engineering and applying DFM improvements (drafts, wall thickness, ribs) for quality and efficiency. Designed and fabricated both molds entirely in-house with my team, performed trials, and validated samples. Delivered production-ready tooling ensuring scalable, defect-free manufacturing.See More

Cookware Hat Stove Base

Cookware Hat Stove Base — DFM & HPDC Cold-Chamber Mold I reverse engineered a stove base, optimized the design for manufacturability, and developed a complete cold-chamber HPDC mold with refined gating, runners, cooling, and ejection systems. Managed in-house fabrication, trials, and refinements with my team, delivering a production-ready mold ensuring high-quality, scalable die casting.See More

Oven Door Handle Base

Oven Door Handle Base — DFM & HPDC Hot-Chamber Mold I reverse engineered and optimized an oven door handle base for manufacturability, then designed a full hot-chamber HPDC mold with gating, runners, cooling, and ejection systems. Managed in-house fabrication, trials, and refinements with my team, delivering a production-ready mold that ensured high-quality castings and scalable manufacturing.See More

6 TON Pneumatic Press

6 TON Pneumatic Press — Mechanical Design & Workshop Engineering I designed and built a 6-ton pneumatic press with constant stroke and adjustable height, fully developed in-house. Created CAD models, performed engineering analysis, and led fabrication (machining, welding, assembly). Tested and validated performance, delivering a reliable, custom-built machine that expanded our workshop’s capabilities.See More

Wrapping Tape Slitting Machine

Wrapping Tape Slitting Machine — Mechanical Design & Fabrication I designed and built a custom slitting machine to cut large rolls of wrapping tape into smaller widths. Created CAD models of unwinding, slitting, guiding, and rewinding systems, with calculations for forces and tension control. Supervised full in-house fabrication, assembly, and testing, delivering a precise, reliable, production-ready machine.See More

Hard Cover Edge Tuner Machine

Hard Cover Edge Tuner Machine — Mechanical Design & Manufacturing I designed and built a custom machine for hardcover finishing, enabling smooth paper folding, timed pressing, and adjustable thickness control. Developed complete CAD design, integrated adjustable mechanisms, and led full workshop fabrication. Validated through trials, delivering a reliable, production-ready machine tailored to customer needs.See More

Pneumatic Paper Press

Pneumatic Paper Press — Mechanical Design & Manufacturing I designed and built a pneumatic press for book binding, delivering high stroke and consistent pressing force to ensure proper adhesion. Developed full CAD design with force/stroke calculations, then supervised in-house fabrication, assembly, and calibration. Validated through trials, providing the customer with a reliable, production-ready solution.See More

File Labeling Machine

File Labeling Machine — Heat Stamping & Timer Control I designed and built a custom heat stamping machine for PVC label cases on file covers, integrating an automatic timer for consistent, reliable adhesion. Created mechanical and thermal design with heated pressing head, added control system, and supervised full in-house fabrication, testing, and calibration. Delivered a production-ready machine tailored to customer needs.See More

Foam Slitting Machine Conveyor

Foam Slitting Machine Conveyor — Design, Manufacturing & Assembly I transformed a customer’s basic drawing into a full conveyor system design for a foam slitting machine. Created CAD models, performed calculations, and fabricated all parts in-house. Supervised on-site assembly and testing, ensuring seamless integration, reliable performance, and a production-ready solution tailored to the customer’s needs.See More

Foam Crane System

Foam Crane System — Mechanical Design, Fabrication & Assembly I engineered a custom crane for a foam warehouse based on area, load, and block specs. Designed structure, trolley, hoist, and wireless control in CAD, with full load analysis. Supervised in-house fabrication and led on-site assembly and testing. Delivered a safe, durable, and fully operational crane tailored to the customer’s needs.See More

Work History

Technical Consultant

Machines & Aluminium CenterLead the transition of new products from R&D to full-scale manufacturing. Responsible for conducting DFM evaluations, planning manufacturing processes, and designing tools required for production. Actively solve production challenges on the shop floor to ensure product quality and efficiency. Oversee R&D efforts within the tool factory, identifying opportunities for improvement, optimizing tool performance, and implementing solutions that enhance productivity and reduce downtime. Role bridges design, engineering, and production to support continuous development.

Deputy General Manager, R&D Manager, Production Manager

Pro TecNov 2004 - Nov 2020 • 16 yrs 1 moAs Deputy General Manager, prepared quotations, engaged in negotiations with customers, managed supplier relationships, and optimized financial and human resources systems. As R&D Manager, specialized in designing molds, dies, and production components, reviewed customer designs for manufacturability, and developed innovative production techniques. As Production Manager, developed and managed production schedules, created CAM programs for CNC milling and wirecut machines, produced technical drawings, and developed detailed process sheets.

Education

Cairo University

Doctor of Philosophy (PhD), Mechanical Design and Production Engineering2011 - 2018

Arab Academy for Science, Technology and Maritime Transport

Master's degree, Industrial & Management Engineering2005 - 2010

Misr University for Science and Technology

Bachelor's degree, Industrial and Systems Engineering1999 - 2004

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