Freelance mechanical design engineer

“Clear ideas become better products.”

SolidWorks CAD, product design, DFM, FEA and manufacturing documentation for startups, product teams and manufacturers worldwide.

A clean process from the first requirement to the final drawing package.
Talha Javed Malik, registered mechanical design engineer
Talha Javed MalikIslamabad · Supporting clients worldwide
Core platformSolidWorks CAD
ManufacturingDFM and GD&T
ValidationStructural and thermal FEA
Delivery modelWorldwide remote collaboration
Mechanical design services

Focused engineering support for each stage of development.

Choose a focused service or combine several into one product development scope. Every service page explains the problem, deliverables, workflow and relevant project evidence.

01

SolidWorks Design Services

Parametric SolidWorks modeling, assemblies and drawing packages for product teams who need CAD that a supplier can actually quote and build from, not just a file that opens cleanly on screen.

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02

Mechanical CAD Services

Full-cycle mechanical CAD, from a rough concept or sketch through detailed assemblies, mechanism design and the documentation a manufacturer needs to quote and build.

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03

Product Design Engineering

Full-cycle product design engineering, from a rough concept, reference image or early prototype through resolved industrial design, mechanical CAD, DFM and a manufacturer-ready documentation package.

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04

Design for Manufacturing

Design for Manufacturing review for injection molded plastics, CNC machined parts and sheet metal assemblies, built into the CAD process from the first model instead of added as an afterthought.

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05

Sheet Metal Design

Sheet metal parts and assemblies modeled in SolidWorks with real bend allowances, correctly developed flat patterns, and fabrication-ready DXF files, not just a folded solid that looks right on screen.

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06

Injection Molding Design

Injection molded plastic part design for consumer products and hardware, with wall thickness, draft angles, snap-fit geometry and rib structure resolved from the concept stage instead of discovered by a mold maker.

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07

Manufacturing Drawings and GD&T

Dimensioned manufacturing drawings and GD&T for machined, molded and sheet metal parts, prepared for real quoting and inspection, not auto-generated views with default tolerances left in place.

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08

Finite Element Analysis

Structural and thermal finite element analysis for enclosures, brackets, actuators and load-bearing assemblies, used to validate a design decision before it is committed to tooling or machining.

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Who the work supports

Engineering capacity that fits the stage of the product.

Projects are structured for teams that need practical mechanical design support without adding unnecessary process or permanent overhead.

Startups and founders

Turn an early idea into reviewable CAD.

Translate sketches, requirements and reference products into a clear concept, assembly structure and prototype ready design.

Product teams

Add focused CAD and DFM capacity.

Support an existing team with detailed modeling, engineering review, simulation and documentation during busy development stages.

Manufacturers and fabricators

Prepare files that are easier to quote and build.

Resolve dimensions, tolerances, flat patterns, bill of materials and supplier feedback before production release.

Selected work

Explore projects visually.

Preview the work from the project dock, then open a case study for the engineering brief, specifications and original presentation.

14 / 14Bench Grinder Assembly for AI Training Dataset
Bench grinder assembly portfolio board
How the work moves

A practical five step workflow.

Every stage produces a clear decision, review point or manufacturing deliverable.

01
Requirements

Define the product

Fit, function, references, materials and target dimensions are agreed before geometry begins.

02
CAD development

Build the CAD system

Parametric parts, multi part assemblies, mechanisms, interfaces and fasteners are developed in SolidWorks or Fusion 360.

03
DFM review

Review manufacturing risk

Moldability, machining access, sheet metal bends, fit relationships and assembly sequence are reviewed before release.

04
Simulation and checks

Validate performance

Structural, thermal and tolerance checks are completed where the product needs evidence rather than assumption.

05
Production documentation

Document the handoff

Drawings, GD&T, bills of materials, exploded views and exchange files are packaged for suppliers and production.

01

Product and Consumer Design

Consumer products, wearable electronics and electromechanical systems designed around real use, assembly and production.

02

Industrial and Mechanical Systems

Mechanical assemblies, structural products and power transmission systems developed with realistic interfaces and validation.

03

Precision and Manufacturing Documentation

Machined enclosures, sheet metal assemblies, GD&T and supplier ready manufacturing drawing packages.

Talha Javed Malik
About Talha

Factory floor thinking from the first sketch.

Talha Javed Malik is a registered mechanical engineer based in Islamabad, working remotely across product design, SolidWorks CAD, DFM, FEA and production documentation.

Projects range from consumer products and wearable electronics to EV hardware, mechanisms, precision enclosures and complete sheet metal manufacturing packages.

14Selected projects
FEAStructural and thermal
DFMManufacturing review
GD&TProduction drawings
Before we begin

Common project questions, answered clearly.

Quick answers about scope, deliverables, collaboration and manufacturing support.

Do you work with clients outside the United States and Australia?

Yes. Mechanical design services are available worldwide. The United States and Australia have dedicated pages because they are priority search markets, not because work is limited to those countries.

What files can be included in the handoff?

Deliverables can include native SolidWorks or Fusion 360 files, STEP and IGES exchange files, DXF flat patterns, manufacturing drawings, bills of materials, exploded views and simulation reports, depending on the agreed scope.

Can you work directly with a manufacturer or supplier?

Yes. Supplier questions, DFM feedback, prototype revisions and drawing updates can be handled as part of the project so the design remains consistent through production preparation.

Which types of products are a good fit?

The portfolio covers consumer products, wearable electronics, EV hardware, mechanisms, precision enclosures, industrial assemblies and sheet metal manufacturing packages.

What should I prepare before making contact?

A useful starting package includes the product objective, reference images or sketches, known dimensions, expected manufacturing method, required files and any timing constraints.

Start a conversation

Choose a direct way to start the conversation.

WhatsApp, Upwork and email are available for project enquiries worldwide.

Useful project brief

A clear first message saves review time.

  • Product objective and main function
  • Sketches, images, scans or existing CAD
  • Known dimensions, materials and manufacturing method
  • Required outputs such as STEP, drawings, BOM or FEA
  • Target dates and supplier constraints
Ready to move forward?

Let’s make the next engineering decision clear.

Share the product stage, current files and the result you need.

Project 01

Gothic Tower Clock Display System

A custom engineering and real-time display build for architectural signage: a bespoke real time software and display engineering build for a large scale Gothic style tower clock, developed to run natively on a NovaStar TB60 controller driving a 2048×2048 pixel P3.91 outdoor LED wall. The clock face was modeled and textured with full Gothic ironwork detailing, including a rose window center, gold filigree numerals and ornate hands, then rigged to a custom real time engine with an automatic day and night rendering mode: crisp, high contrast matte faces for daylight legibility, and a softer backlit glow after dark to avoid glare for nearby drivers and pedestrians. Every asset was mathematically mapped to the exact LED pixel grid for edge to edge sharpness with minimal scaling distortion, and the software was built to hold up to continuous 24/7 outdoor runtime.

Gothic tower clock face photorealistic render with ornate gold and black dial detailing
Photorealistic render of the gothic tower clock face, mathematically mapped to a 2048×2048 px P3.91 outdoor LED wall.
Real Time SoftwareLED Display EngineeringDay and Night Rendering
Display2048×2048 px, P3.91 LED
ControllerNovaStar TB60
Project 02

Precision Wind Direction Indicator

Outdoor product design engineering for precision instrumentation: a weatherproof wind vane instrument engineered for airports, helipads and industrial rooftops. Aluminum and stainless construction with a powder coated finish and a two knob pole clamp sized for 40 to 60 mm masts, built for precision reading and low maintenance outdoor service.

Precision wind direction indicator mounted on pole
Assembly render showing a powder coated aluminum vane on a two knob pole clamp for outdoor deployment.
Product DesignOutdoor HardwareAluminum + Stainless
MountØ40 to 60mm pole
FinishPowder coated
Project 03

On the Go Baby Formula Feeding Container

Consumer product design and DFM for injection molding: a compact, travel ready feeding container built around a 120 ml formula chamber and 180 ml water reservoir, with a leak resistant lid and a one hand secure lock. Taken through research, concept exploration and SolidWorks development with DFM in mind, finished with a detachable strap for diaper bag carry.

On the go baby formula feeding container exploded view
Design approach, exploded BOM and real life carry context for the feeding container.
Consumer ProductIndustrial DesignDFM
Capacity120ml + 180ml
CareDishwasher safe
Project 04

EV Battery Pack Enclosure

EV battery enclosure design with FEA thermal and structural validation: a 12 module lithium battery enclosure machined from 6061 T6 aluminum, designed toward an IP67 rating with a structural Factor of Safety of 2.4. Ansys Thermal and Ansys Mechanical studies indicated a 55.3 °C peak temperature and 132.6 MPa peak stress, both inside spec, before the 15 item BOM and manufacturing drawing were prepared.

EV battery pack enclosure SolidWorks assembly with thermal and structural FEA
Assembly, exploded view, thermal & structural FEA, manufacturing drawing and validation summary.
FEA, Thermal and StructuralEV HardwareManufacturing Drawing
Max stress132.6 MPa (FoS 2.4)
Max temp55.28 °C
Project 05

Smart LED Glasses

Wearable electronics product design for SLS 3D printing: reengineered the temple housings of an existing smart glasses platform to fit a custom PCB, battery, LED strip and speaker. Wall thickness, snap fit clearance and rib structure were tuned specifically for SLS 3D printing, keeping the frame light and comfortable enough for all day wear.

Smart LED glasses product design with electronics integration exploded and section views
Final assembly, internal exploded components, and section view showing wall thickness and snap-fit detail.
Electronics IntegrationWearable TechSLS Printing
Wall thickness1.8mm
SoftwareFusion 360
Project 06

Modular Lunchbox System

Consumer product assembly design with sealing and latch mechanisms: a four compartment lunchbox assembly with a gasketed, leak resistant lid, dual pivot latches and a removable insert tray, fully defined in SolidWorks with mate driven exploded documentation ready for supplier handoff.

Modular lunchbox system exploded SolidWorks assembly
Exploded assembly: lid, seal gasket, insert tray, dual latches and pivot hinges.
Assembly DesignSealing SystemsConsumer Product
Compartments4
SoftwareSolidWorks 2024
Project 07

Ergonomic Handheld Power Tool Housing

Ergonomic electromechanical product design for injection molding: a pistol grip housing for a handheld power tool, built around an overmolded soft touch grip, a rotary dial, trigger button and PCB mount plate. Every subassembly, including the upper and lower housing, battery pack, switch assembly and LED light pipe, is captured in the exploded release drawing for a clean supplier handoff.

Ergonomic handheld power tool housing final assembly render
Handheld power tool housing exploded view with PCB battery and switch assembly
Final housing assembly (left) and full exploded release showing PCB, battery pack and switch assembly (right).
Ergonomic DesignOvermoldElectromechanical
GripTPE overmold insert
AssemblyM3 heat set inserts
Project 08

Precision Cordless Screwdriver

Mechanism design engineering for configurable electromechanical products: a configurable cordless driver built around a 7.2 to 1 planetary gearbox and a coreless 12V, 16,000 RPM DC motor, powered by an integrated BMS lithium cell. A custom 32 bit control PCB drives an LED ring indicator and haptic feedback, with Precision, High Torque and Service configurations managed from one master model.

Precision cordless screwdriver final assembly
Cordless screwdriver exploded view showing planetary gearbox, DC motor and lithium battery
Final housing (left) and driveline exploded view: planetary gearbox, DC motor, battery and control PCB (right).
Mechanism DesignElectromechanicalConfiguration Mgmt.
Motor12V, 16,000 RPM coreless
Battery12V 800mAh / 9.6Wh
Project 09

Planetary Gear Actuator

Precision machining and GD&T drawing package for power transmission hardware: a high performance planetary actuator designed for a target torque of 12,000 Nm at up to 3,200 rpm and 45 kW peak power, with an eight part driveline including the sun gear, planet carrier, ring gear, clutch and output shaft, toleranced to a target Ra 1.6 µm and prepared as a production drawing with GD&T.

Planetary gear actuator manufacturing drawing exploded view
Full driveline exploded view with dimensioned orthographic views and detail callout.
Power TransmissionPrecision MachiningGD&T
Max torque12,000 Nm
Peak power45 kW
Project 10

Rugged Handheld Instrument Enclosure

Precision machined enclosure design with tight tolerance GD&T: a machined aluminum housing for a handheld field display unit, with a 50×80 mm active display opening, a 24 pin connector port and Helicoil reinforced mounting bosses. Pocket depths, wall thickness and bore tolerances are defined with a critical tolerance target of ±0.02 mm, finished in black hard anodize for outdoor durability.

Field instrument enclosure machined aluminum drawing with front back and section views
Front, back, section and mounting interface detail views for a handheld field instrument housing.
Precision MachiningGD&THandheld Electronics
MaterialAluminum 6061 T6
FinishBlack hard anodize, Type III
Project 11

Rugged Sensor Enclosure

IP67 sealed enclosure design for optical and sensor hardware: a CNC machined aluminum enclosure with a removable lid for an optical sensor module, designed with an AS568 125 O ring groove for IP67 sealing intent. Mounting centers, lid fastener spacing and the O ring groove are held to tight positional tolerance, with mating faces finished to a target Ra 1.6 µm.

Rugged sensor enclosure CNC machined aluminum drawing with O ring groove detail
Front, top, side and section views with O ring groove and datum reference detail.
IP67 SealingPrecision MachiningOptical Hardware
MaterialAluminum 6061 T6
SealingIP67, O ring AS568 125
Project 12

Countertop Convection Oven Assembly

Sheet metal DFM and full manufacturing drawing package: a complete 19 sheet manufacturing package for a countertop oven, including a powder coated AISI 316 front panel, insulated food chamber, top, bottom and back insulation covers, an aluminum extrusion frame, a glass and steel door assembly, and a linear actuator door mechanism, with every part released with flat pattern development and bend data.

Countertop convection oven full assembly manufacturing drawing
Sheet 1 of 19, full assembly with 36 item bill of materials.
Sheet Metal DesignFlat Pattern DevelopmentFull Drawing Package
Parts36 item BOM
ToleranceASME Y14.5M 1994
Project 13

Oven Door and Food Chamber Subassembly

Mixed-material sheet metal and glass assembly design: an eight part glass and steel oven door, including the main frame, front and back frames, four glass brackets and tempered glass, paired with a fully dimensioned 316 steel food chamber flat pattern, insulated on all sides and sized for a linear actuator driven open and close mechanism.

Oven door subassembly and food chamber drawing
Door subassembly and food chamber flat pattern, sheets 4 and 11 of 19.
Sheet MetalGlass & Steel AssemblyLinear Actuation
Door parts8 item assembly
Chamber materialAISI 316 steel
Project 14

Bench Grinder Assembly for AI Training Dataset

Multi-part mechanical assembly CAD for AI training datasets: an original multi part bench grinder developed as a generic mechanical product assembly for AI training. The project was built as a believable CAD system with a stable motor housing, shaft assembly, abrasive wheels, wheel guards, transparent eye shields, adjustable tool rests and a compact base with an integrated switch.

Bench grinder assembly portfolio board
Portfolio board showing the assembled product, CAD development view, exploded structure, bill of materials, workflow and orthographic views.
Multi Part AssemblyCAD DatasetDocumentation Ready
Assembly scope18+ parts
DeliverablesSTEP, BOM and construction logic