info: Germany, Austria, Switzerland, United Kingdom, Netherlands, Poland
MSc Eng – Automation and Robotics, AGH University of Krakow
Cracow, Poland
Germany +5
info: Germany, Austria, Switzerland, United Kingdom, Netherlands, Poland
MSc Eng – Automation and Robotics, AGH University of Krakow
Profile attachments
Rafal_Gaszynski_Senior_Mechanical_Engineer_CV.pdf
About me
I help product teams turn complex mechanical and electromechanical requirements into manufacturable hardware. With 20+ years in engineering and nearly 5 years in international contracting, I bring end-to-end design ownership, practical DFM and a collaborative approach.
Senior Mechanical Engineer with 20+ years of experience in mechanical product development and integration of complex mechanical, electromechanical and optomechanical products. Experienced across the full product development lifecycle, from concept and RFQ through detailed design, engineering release and production support.
CORE ENGINEERING EXPERTISE
Mechanical product development, mechanical design, system packaging and mechanical integration.
Component and assembly design, interface definition, design feasibility and packaging studies.
GD&T (ASME Y14.5), datum systems, tolerance stack-up analysis and dimensional engineering.
Design for Manufacturing and Assembly (DFM/DFA), design reviews, supplier and toolmaker collaboration.
Engineering change management, production documentation, engineering release and manufacturing support.
CAD & PLM
CATIA V5 — Expert, 15,000+ hours: Part Design, Generative Shape Design (GSD), Assembly Design and Drafting.
Siemens NX — Expert, 12,000+ hours: solid and surface modelling, assembly design and production drawings.
Teamcenter Engineering — Advanced.
Dassault Systèmes 3DEXPERIENCE — hands-on experience during PLM rollout.
MATERIALS & MANUFACTURING
Injection-moulded plastic components, including housings, carriers, covers, lenses and light guides.
Aluminium die-cast components, sheet-metal parts and assemblies.
Composite components, including CFRP/carbon fibre and fibreglass.
PRODUCT & SYSTEM EXPERIENCE
Electronics packaging, PCB integration, electromechanical assemblies and mechanical interfaces.
Automotive interior systems, ambient lighting, optical components, displays, head units and electrical connectors.
Optomechanical integration of housings, PCBs, lenses and light guides, working with optical, electronics and thermal engineering teams.
PROFESSIONAL BACKGROUND
Engineering experience at Varroc, Aptiv and Delphi, complemented by nearly five years of international freelance and contract engineering assignments in Germany and Poland. Experienced in direct customer collaboration and cross-functional development in international engineering teams.
CONTRACT INTERESTS
Open to medium- and long-term mechanical engineering and product development assignments, preferably remote or hybrid. Part-time support and selected full-time contracts are considered subject to scope, scheduling and agreed availability. Client-authorised commercial CAD and PLM access required for CATIA V5 / Siemens NX assignments.
Mechanical development and integration of automotive ambient lighting systems and complex optomechanical assemblies.
Key responsibilities:
Mechanical ownership of components, subassemblies and assemblies across multiple vehicle locations.
Design and development of injection-moulded carriers, housings, lenses, light guides and light engine assemblies integrating PCBs and optical components.
Detailed mechanical design and production documentation in CATIA V5, including GD&T and tolerance stack-up analysis.
Resolution of mechanical packaging, interface, assembly and manufacturability challenges.
DFM/DFA, feasibility studies, design reviews and collaboration with suppliers and toolmakers.
Direct customer collaboration and cross-functional development with optical, electronics and thermal engineering teams.
Engineering release, change management and production-oriented design improvements.
Mechanical support for camera and ECU RFQ and concept development, including plastic housings, aluminium heatsinks, PCBs and lenses.
Mechanical design and development of railway interior systems, including ceiling, sidewall and kitchen/bar area components for passenger rail vehicles.
Key responsibilities:
Mechanical design of interior components and assemblies using sheet metal, fibreglass and rubber.
Detailed CAD development and modification of existing designs in CATIA V5.
Design feasibility studies and resolution of mechanical integration and packaging issues.
Implementation of engineering changes in accordance with project requirements.
Mechanical development of lightweight automotive composite components as part of a project focused on replacing conventional steel components with carbon fibre-reinforced polymer (CFRP) alternatives.
Key responsibilities:
Design and development of CFRP components for automotive body and closure applications.
Adaptation of component geometry to composite material requirements and existing vehicle interfaces.
Detailed CAD development and surface modelling in CATIA V5.
Design feasibility studies and implementation of engineering changes.
Direct collaboration with the customer engineering team during an onsite assignment in Munich, Germany.
Contract Mechanical Design Engineer – Panoramic Roof Systems
CADM Automotive
Automotive & Vehicle Manufacturing
Concept development and mechanical design of components and assemblies for automotive panoramic roof systems, involving plastic, steel, aluminium and rubber components.
Key responsibilities:
Mechanical design and development of panoramic roof components during the concept phase.
Creation of 3D CAD models and GD&T-based 2D engineering documentation in CATIA V5.
Mechanical integration of components within assembly and vehicle packaging constraints.
Design feasibility studies, engineering changes and engineering data management.
Coordination of engineering activities within the Kraków design team.
Coordination of technical collaboration between German and Polish engineering teams.
Direct customer collaboration during an onsite assignment in Stuttgart, Germany.
Mechanical product development of automotive electronic and mechatronic systems, including integrated control panels, steering wheel switches and gearshift-related components.
Key responsibilities:
Mechanical design and development of injection-moulded plastic and silicone components for automotive mechatronic assemblies.
Detailed design, 3D modelling and GD&T-based production documentation in CATIA V5.
Mechanical integration of components within complex electromechanical assemblies.
Tolerance stack-up analysis, design feasibility studies and resolution of dimensional and assembly issues.
Engineering change management, design release and engineering data management using Teamcenter Engineering.
Production support and resolution of design and manufacturing issues.
Delivery of internal CATIA V5 training for mechanical engineers.
