Khaled Elfakharany
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freelance

Freelance Product Designer

Various Clients
Feb 2015 - Apr 2017 (26 months)
Cairo, Egypt
Team of 1
Overview

Khaled operated as an independent product designer specializing in mechanical design and prototyping for diverse clients, ranging from factories seeking electronics enclosures to startups developing innovative consumer products. Working concurrently with Qafeer Makerspace, he leveraged advanced CAD/CAM tools and simulation software to deliver manufacturing-ready designs. The highlight of this period was designing a self-following luggage prototype for an investor-backed startup, combining mechanical engineering with IoT concepts to create a device that would autonomously follow its owner through airports.

Why I Joined

Passion for combining robotics knowledge with mechanical design skills, plus opportunity to work on diverse client projects while building expertise at the makerspace

Responsibilities
  • •Designed custom electronics enclosures for factory clients requiring prototypes for new product launches, ensuring designs met manufacturing tolerances and assembly requirements
  • •Developed IoT device housings including coffee machines and smart appliances, integrating mechanical design with electronic component considerations
  • •Created PCB enclosures that properly accommodated circuit boards while managing thermal, EMI, and accessibility requirements
  • •Performed stress testing and structural validation using SolidWorks Simulation (Finite Element Analysis) to ensure designs could withstand real-world use
  • •Prepared designs for manufacturing using Fusion 360 CAM and SolidCAM, generating toolpaths for CNC machining and other production processes
  • •Consulted with clients on material selection, manufacturing processes, and design optimization to balance quality with cost constraints
Key Achievements
  • ✓Designed and delivered self-following luggage bag prototype for investor-backed startup, combining mechanical design with IoT sensor integration to create autonomous airport navigation capability
  • ✓Completed multiple electronics enclosure projects for factory clients, delivering manufacturing-ready designs that met production tolerances and timeline requirements
  • ✓Established comprehensive CAD/CAM workflow using SolidWorks, Fusion 360, and SolidCAM that enabled efficient transition from concept to manufacturable design
  • ✓Delivered IoT device housings including coffee machine prototypes, successfully integrating electronic component requirements with aesthetic and functional mechanical design

Technology Stack

Primary Technologies
SolidWorksFusion 360 CAMAutoCAD
Secondary Technologies
SolidCAMSolidWorks SimulationSolidWorks VisualizeEagle PCB
Infrastructure
CNC machining equipment3D printersLaser cutting machines
Tools
Technical drawing toolsMeasurement instrumentsPrototyping equipment
Methodologies
Design for ManufacturingIterative prototypingClient consultation
The Story

Situation

An investor-backed startup approached Khaled with an ambitious concept: a luggage bag that could autonomously follow its owner through busy airports, eliminating the need to drag heavy bags through terminals.

Task

Khaled needed to design the complete mechanical system for this self-following luggage, integrating motor housings, sensor mounts, battery compartments, and structural components while keeping the design manufacturable and within weight constraints.

Action

Using SolidWorks as the primary design tool, Khaled created a comprehensive 3D model integrating all mechanical systems. He performed stress analysis using SolidWorks Simulation to ensure the structure could handle the dynamic loads of autonomous movement. The design carefully balanced the weight distribution between the battery pack, motors, and cargo space. He created detailed 2D drawings in AutoCAD for manufacturing specifications and used Eagle PCB to ensure the electronics enclosures would properly accommodate the control boards.

Result

Delivered a complete prototype design that demonstrated the feasibility of the self-following luggage concept. The project became the most memorable work from this period, combining Khaled's passion for robotics with mechanical design skills. The skills developed during this freelance period directly enabled later robotics projects including the P&G warehouse automation robot.

Team Structure

Size: 1 people

Structure: Independent contractor with client collaboration

Reported to: Various clients

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Skills Developed

Skills Gained

Advanced SolidWorks proficiencyCAM programming and manufacturing preparationFinite Element Analysis for design validationIoT device design integrationClient relationship management

Skills Deepened

3D mechanical designDesign for Manufacturing principlesPCB enclosure designRapid prototyping
Key Learnings
  • 💡Designs must be manufacturable, not just visually impressive - understanding production constraints from the start saves significant time and cost
  • 💡Different industries impose different design constraints, requiring adaptability and continuous learning
  • 💡Comprehensive CAD/CAM/simulation workflows enable faster iteration and higher confidence in final designs
  • 💡Freelance work builds expertise through variety, exposing designers to diverse challenges and requirements