Karol Chwałek

• CAD Design Projects: Managing 350+ projects (over 18 months) in the design and creation of rubber press moulding tools and precision components (i.e. milling; turning) used in 3D manufacturing.

• Client Projects: Managing end-to-end projects (4-5 at once) within a team and own initiative from concept (sketches) to create approved CAD drawings - meeting precise client requirements / technical specifications.

• Key Stakeholders: Working directly with line managers, team members, Quality Assurance (ISO standards), Health & Safety, Production Team and client companies (i.e. aerospace, automotive, medical, motorsport, oil & gas, domestic).

• 2D & 3D Modelling: Using 2D & 3D modelling software to design shape, height / width variables and work with the shop floor to accept job files for milling & turning CNC machines.

• Quality Assurance: Working with the QA Team to issue jobs ready for the shop floor, including discussions, problem solving and gaining customer approval for different scenarios (i.e. between 2 and 60 parts per tool).

• Part Configurations: Configuring parts to high tolerances (two microns), accurate measurements, allowing for shrinkage from cooling (high temperatures up to 200⁰C), cavities and metric versus imperial dimensions.

• Materials (Grades): Choosing materials to meet a very specific function, purpose, strength or tolerance using stainless steel - selecting best options according to cost, quality and grades, aligned to client budget needs.

• Production Prototypes: Finding optimal solutions - selecting best manufacturing methods, managing queries, making changes (adjustments; dimensions) and assessing how it impacts the shop floor and QA standards.

• Project Governance: Using Autodesk Vault to access new and existing templates saved onto the database, plus ensuring file storage, valid QA documentation, special reports (Drawing Office) and intellectual property.

• Training & Development: A fast learner via direct collaboration with vastly more experienced colleagues to benefit from 1-2-1 coaching (guidance), practical skills training and problem-solving for diverse scenarios.

• CAD Design Projects: Designed robotic line paint jigs for spraying interior parts / car frames for automotive manufacturers, notably Aston Martin, Rolls Royce, Bentley, Ford, Jaguar, JCB, Land Rover, Honda & Toyota.

• Project Coordination: Managed 10-15 projects weekly ranging from holding solutions to full jig solutions as well as updating databases, data file storage (physical / electronic copies) and working to precise standards.
• Automotive Solutions: Used 2D & 3D modelling software to design paint jigs with stainless steel and mild steel laser plates, round bars, tubes and box sections to client needs (size, thickness & tolerances).

• Team Collaboration: Worked within a dedicated team of 4-8 CAD Design Engineers (reported to Design Work Manager), sharing knowledge (problem-solving skills), achieving deadlines and meeting client specifications.

• Quality Assurance: Inspected fixture positions (precise dimensions) and repaired damaged jigs (TIG welding), plus parts fitting, QA testing, production prototypes, safety standards, extra laser plates and documentation.

• Client Relationships: Worked directly with clients on CAD design solutions, technical drawing preparation, approvals (clear recommendations) and using special programmes for Bystronic laser production techniques.

• Team Leader: Supervised team (3 people) to meet strict deadlines for complex production, maintenance and repair operations projects for Sikorsky helicopters, Boeing 777 & 737 aircraft and automotive customers.

• Safety Critical: Worked to high specifications for Airbus, Boeing and Sikorsky Helicopters by following strict standard operating procedures (welding helicopters), special gases, materials and technical documentation.

• Quality Inspections: Creating TIG tests to meet specific Civil Aviation Authority (CAA) requirements (AWS D17.1 Class A), plus performed triple quality assurance checks on airframe protection, blankets and engines.

• Training Supervision: Trained new operators on manufacture, resistance welding, health & safety and quality assurance, including inductions, 1-2-1 coaching, marking out sections, technical drawings and specifications.

CUSTOMER PROJECTS (PROJECT COORDINATION)
• Created Sikorsky Helicopter heat shields and fire protection blankets
• Boeing 777 fire blankets (repairs); manufactured Boeing 737 metallic blankets
• Created heat protection shields for automotive customers, notably Aston Martin; World Rally Championship (WRC) exhaust systems and Formula 1
• Built covers for FADEC units (electronic engine control units) involving sheet metal assemblies with integral insulation using Spot, Seam and TIG welding techniques
• Resistant welding using very thin light weight foil sheet metal blanks (Rolls Royce & Airbus 380 engine builds).