Nathan Zhang
Senior Mechanical Engineer & Simulation Specialist
Mechanical Design · FEA & CFD Simulation · Thermal Engineering · 20+ Years
Highly experienced Mechanical Engineer and Certified SOLIDWORKS Professional with 20+ years spanning consumer electronics, industrial product development, and electromechanical systems. Specialising in mechanical design, FEA structural/thermal/fatigue simulation, CFD flow analysis, and full-lifecycle product development from concept through mass production.
// expertise
Technical Skills
Simulation & Analysis
CAD & Design
Manufacturing & Quality
Project & Product Management
// portfolio
Projects
Selected engineering work and case studies
Grainfather G70 — Thermal & Hydraulic Redesign
Led full mechanical redesign of the Grainfather G70 homebrew system at Bevie. Delivered significant improvements in thermal performance, hydraulic flow efficiency, product safety and manufacturing quality through SOLIDWORKS modelling and flow simulation.
Outdoor Payment Terminal — Thermal CFD Analysis
Thermal management of an outdoor payment terminal under extreme solar radiation and high ambient temperatures. Conducted conjugate heat transfer CFD simulation (SOLIDWORKS Flow Simulation) to identify CPU overheating and card-reader hot spots, then validated optimised airflow and heat sink solutions to restore system stability.
FEA Study — Magnetic Reader Head Movement
Comprehensive FEA study to diagnose critical mechanical failures: high resistance force during operation and FPC cracking. Performed full simulation workflow — geometry cleanup, meshing, boundary conditions and post-processing — to identify stress concentrations, then proposed and validated structural modifications to eliminate crack propagation and restore smooth kinematic movement.
Sony L55t — Flagship Metal Frame Smartphone
Led mechanical engineering for this flagship 5.2" Sony smartphone featuring a premium precision-engineered metal frame. Addressed structural challenges of metal chassis rigidity, antenna clearance and aesthetic finish. Directed tooling concept through CNC fixtures and successive manufacturing trials to meet Sony mass production quality standards.
Sony J10 — Mobile Phone Mechanical Design Lead
Served as mechanical lead for the J10 mobile phone programme, directing the team from concept through high-volume mass production. Defined overall structural architecture, designed major structural parts and developed an innovative keypad concept optimising tactile feedback and long-term durability.
Sony K530 — Mechanical Architecture & Manufacturing
Lead mechanical architect for the K530 mobile phone, managing the full lifecycle from concept to mass production. Engineered the structural framework using plastic injection moulding and metal insert moulding (MIM) to balance aesthetics with structural integrity. Conducted on-site troubleshooting during production ramp-up to maintain yield and quality standards.
// hire me
Work With Me
Available for senior mechanical engineering roles and consulting engagements.
Simulation & Analysis
Structural, thermal, fatigue and flow simulation consulting
Mechanical & Product
Full-lifecycle design from concept to mass production
DFM & Quality
Injection moulding, tooling, supplier management & DFM
Based in Auckland, New Zealand · Available globally for remote work
Consulting services offered through Vektor Engineering