David Metcalf

Manufacturing R&D for Trelleborg's range of composite bearing products

MetLase started out within Rolls-Royce producing precision fixtures for aerospace manufacturing. Now part of Unipart, it's diversified into automation and robotics. Responsibilities included design of fixtures in Siemens NX to support various manufacturing processes, and supporting ongoing development of an autonomous mobile robot. Played a major role in winning a large order for a heavy-duty precision welding fixture for the defence industry.

Leading the design of a whole new generation of folding guest beds for the UK's leading manufacturer, reporting to the operations director. Released in 2024, the new product range represents a ground-up redesign using automotive-grade recycled plastics moulded here in the UK. With a modular construction, the new range is adaptable to changing market demands and modern assembly methods. All plastic parts were 3D printed in-house for initial validation, before being sampled in high-volume injection mould tools by a specialist supplier. Parts and assemblies were tested to destruction using equipment of my own design, before being independently tested and certified as complete products by FIRA.

Developing re-usable storage systems as part of Kite's specialist bespoke design team. Projects included lightweight transit packs for jet engine nacelles, and heavy-duty thermoformed trays for efficient stacking of cast aluminium components. Responsibilities included the setup and ongoing administration of SolidWorks PDM for the design team, managing design files, and implementing automatic revision control within a completely bespoke drawing template.

Managing the design and installation of bespoke height safety systems for fall protection and rope access, applying detailed knowledge of system types and safety standards for working at height. Day-to-day activities included site surveys, quotations, project planning and regular communication with customers and suppliers. Each site was different, so it was often necessary to produce bespoke steel components to interface between height safety systems and various structures. 3D design of components was done in SolidWorks and system layouts were drawn up in AutoCAD LT. Each project required risk assessments, method statements, operation manuals and the procurement of all components needed for the installation.

Highly selective military leadership training as part of the rigorous 44-week Commissioning Course undertaken by all regular officers of the British Army. Decided to leave Sandhurst to pursue a career in civilian project management and design.

A total of eighteen weeks over two summers, gaining hands-on experience of site operations and mining engineering. Based at the Timmins West underground gold mine in Ontario, Canada.