Engineering Projects

A showcase of mechanical design, machine development, CAD modeling, and automotive engineering solutions.

Tray, canopy, and toolbox concept design proposal for the South African market • SolidWorks, FEA, Microsoft Office (Word, Excel, PowerPoint), Microsoft Team

Isuzu RG06 Utility Body Concept Development

This project demonstrates my ability to transform a vehicle platform requirement into a complete accessory concept package that supports real-world utility, manufacturability, and visual appeal. Each design concept was developed to enhance the functionality of the Isuzu RG06 while maintaining a professional, integrated look aligned with commercial vehicle expectations in the South African market. The resulting proposal presents a flexible utility solution: an open tray for practical load carrying, a canopy for protected cargo use, and a toolbox system for organised secure storage. Together, these concepts highlight a design approach centred on functionality, modularity, and production-conscious detailing.

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Automotive Design • SolidWorks, FEA, Microsoft Office (Word, Excel, PowerPoint), Microsoft Team

Ford Ranger Aluminium Canopy

I was assigned to design and develop an aluminium canopy concept for the Ford Ranger, prepared as a proposal for Ford Motor Company in South Africa. The project focused on creating a strong, functional, and visually refined canopy solution that aligns with OEM expectations for durability, safety, practicality, and vehicle integration. The canopy design uses aluminium as the main structural material, combined with glass and rubber components to support sealing performance, visibility, weather protection, and long-term usability. The specified finish includes E-coating and spray painting, providing enhanced corrosion resistance, surface protection, and a clean automotive-grade appearance. Key product features include an OEM centre high-mounted stop lamp (CHMSL), sliding windows, an integrated locking system, and an air vent system. These features were incorporated to improve safety, accessibility, ventilation, security, and user convenience while maintaining a practical design suitable for both commercial and lifestyle applications. The design is currently pending approval, representing an important stage in the product development and OEM proposal process. This project demonstrates my dedication to automotive product design, attention to technical detail, and ability to develop solutions that meet professional industry standards and customer-focused requirements.

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Automotive Design • SolidWorks, FEA, Microsoft Office (Word, Excel, PowerPoint), Microsoft Team

Design of Mahindra Drop-Side Tray

I designed and developed a robust Drop-Side Tray solution for Mahindra Pik UP, engineered to deliver practical utility, structural strength, and reliable performance in demanding working environments. The tray was developed with a strong focus on durability, ease of use, payload capability, and market readiness, ensuring it meets the functional expectations of both commercial and everyday users. To verify the integrity of the design, I conducted Finite Element Analysis (FEA) to assess structural performance under load conditions and identify areas requiring reinforcement or optimization. This engineering validation process helped ensure that the tray design was robust, reliable, and capable of safely supporting a 1-ton load capacity. Following the design and analysis phase, the Drop-Side Tray successfully passed road testing, confirming its real-world performance, durability, and suitability for operational use. As a result of the successful validation process, Mahindra South Africa approved the product, and the tray has since been introduced to the market. This achievement reflects a high level of dedication, technical commitment, and attention to detail throughout the development process. From concept and structural analysis to testing and market approval, the successful launch of the Mahindra Drop-Side Tray demonstrates the value of disciplined engineering and persistent effort in delivering a commercially approved product.

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Automotive Accessories Design • SolidWorks, Microsoft Office (Word, Excel, PowerPoint), Microsoft Team

Mahindra Pik Up Rear Bumper with Towbar Concept Design

These two-rear bumper with towbar concepts were developed and presented to Mahindra South Africa for approval and potential use on the Mahindra Pik Up bakkie. The design objective was to create a strong, functional, and visually integrated rear protection system that supports a 2.5-ton towing capacity while complementing the vehicle’s rugged utility profile. Both concepts were designed to follow the profile of the vehicle at the rear corners, creating a clean transition between the bumper and the body shape. This approach helped maintain the original styling language of the Mahindra Pik Up while adding a more robust and practical rear-end solution. The first concept features a lower step point, offering easier access to the load bin while keeping the towbar assembly positioned for practical daily use. The second concept introduces an upper step point, giving the bumper a more aggressive and elevated appearance while retaining functional access and rear protection. Together, the two options demonstrate how design variation can address both usability and styling requirements for commercial and lifestyle bakkie applications.

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Automotive Accessories Design • SolidWorks, Microsoft Office (Word, Excel, PowerPoint), Microsoft Team

Isuzu RG06 Bakkie Sport Bar Concept Design

As part of a concept design presentation for Isuzu, I developed a range of sport bar design options for the Isuzu RG06 bakkie. The objective was to explore styling, functionality, and manufacturable design solutions that would complement the vehicle’s rugged character while meeting customer expectations for a strong, practical, and visually distinctive accessory. A total of seven sport bar concepts were presented to Isuzu for review and approval. Following the evaluation process, two concepts were selected for further development: the X-Rider Plate Concept and the Extended Rear Tube Concept. These selected designs reflected the preferred balance between visual appeal, structural presence, and compatibility with the Isuzu bakkie platform. The sport bar concept consisted of a front tube and rear tube assembly, connected by side plates to create a cohesive and robust profile. The design also incorporated sill mount brackets to support secure fitment and integration with the vehicle body. This project demonstrates my ability to translate customer requirements into multiple design directions, present clear concept options, and refine selected designs for approval and development.

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Automotive ROPS Design • SolidWorks, Microsoft Office (Word, Excel, PowerPoint), Microsoft Team

HALO ROPS VAN & BUS - Project

ROPS / HALO Vehicle Safety System I was responsible for designing and developing vehicle-specific ROPS / HALO fitment solutions for mining-sector vehicles in collaboration with Safety Engineering International. This involved adapting the HALO system to suit different vehicle platforms while supporting safety, installation, and manufacturing requirements. HALO is a proprietary rollover protection system developed by Safety Engineering International. It is designed to work with a vehicle’s existing structure to distribute rollover impact forces more evenly, reduce concentrated loading, and help minimize roof intrusion around key occupant areas. My contribution focused on engineering design, vehicle integration, fitment development, technical documentation, and support during implementation. Note: HALO is a product of Safety Engineering International. More information is available at www.halorops.com.

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Automotive ROPS Design • SolidWorks, Microsoft Office (Word, Excel, PowerPoint), Microsoft Team

ROPS / HALO Vehicle Safety System Project

I was given the responsibility to design and develop ROPS / HALO fitment solutions for various vehicle platforms used in the mining sector, working in collaboration with Safety Engineering International. The project involved adapting the HALO system to suit different vehicle body structures while supporting the required safety, packaging, and installation requirements for mining applications. HALO is a rollover protection system developed by Safety Engineering International. The system is designed to work with the vehicle’s existing geometry to help distribute rollover impact forces across the vehicle body structure, reducing concentrated loading in any single area. Its design approach supports controlled rollover behaviour by maintaining the vehicle’s roll-radius characteristics and distributing roof loads more evenly across the roof structure. This helps reduce roof intrusion around key structural areas such as the A- and B-pillars, contributing to improved occupant protection during rollover events. My role focused on the engineering design and vehicle-specific adaptation of the HALO system, including developing fitment concepts, supporting design validation, preparing technical documentation, and collaborating with the relevant engineering teams to support implementation. Key Responsibilities and Contributions: Designed and developed vehicle-specific ROPS / HALO fitment solutions for mining-sector vehicles. Collaborated with Safety Engineering International to align the design work with the intended HALO product requirements. Supported the integration of the HALO system with various vehicle platforms while considering vehicle geometry, fitment constraints, and installation practicality. Prepared technical design documentation to support manufacturing, installation, and project execution. Contributed to the implementation of rollover protection solutions intended for demanding mining environments. Note: HALO is a proprietary product of Safety Engineering International. For more information, visit www.halorops.com.

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Automotive Design • SolidWorks, FEA, Microsoft Office (Word, Excel, PowerPoint), Microsoft Team.

Nissan Underbody Transfer Cover Project

Nissan Underbody Transfer Cover Project In 2021, I contributed to the Nissan Underbody Transfer Cover project by completing the component design, performing FEA validation, preparing manufacturing drawings, creating fitting instructions, and compiling the bill of materials. I also supported the process engineering team during manufacturing implementation. This work helped ensure the design was production-ready, clearly documented, and aligned with manufacturing requirements.

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Automotive Design • SolidWorks / Microsoft office (Excel, word, PowerPoint)

Vehicle Accessories Product Design

Vehicle Accessories Product Design – OEM Project As a Design Engineer at AeroklasDuys, I was responsible for the product design and development of mild steel and stainless-steel vehicle accessories for an OEM customer in South Africa. During the 2019 conceptual design phase, four product concepts were developed, presented, and approved by the customer. The approved concepts included stainless-steel and mild steel tube configurations, with variations incorporating center high-mounted stop lamp (CHMSL) provision and aluminum extrusion cross bars linking the front and rear tubes from the sides. This project demonstrated my involvement in early-stage concept development, product configuration, customer approval processes, and the design of vehicle accessory solutions suitable for OEM requirements.

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