ThomasMgbor
ProductDesignEngineer
tommgbor@gmail.com @thomasm.design /in/thomas-mgbor/ www.thomasm.design
Education
QueenElizabeth’sSchool,Barnet ALevels:ProductDesign(A*),Geography(A*), MathematicsB,ExtendedProjectA,ASGermanA 20142021
20222026
LoughboroughUniversity
MEngProductDesignEngineering
FirstYear:FirstClass,SecondYear:FirstClass, ThirdYear:FirstClass
RelevantExperience
BritishAirways
SupportedDissertation 2025-
20242025
2024
BromptonBicycle
SupportedDissertation
Batch.Works
R&DandProductionIntern
IntelligentAutomationCentre,LoughboroughUniversity ResearchIntern 2023
20212022
Batch.Works&Batch.Space Design,R&D,andProductionIntern
WorkshopTechnician
Variousotherworkexperience:Foster+Partners2021,BromptonBicycle2021, Google2021,MorganLovell20192020,CreateConsultingEngineersLtd2019
Engagedwiththeiterativedesignprocesswith productscomprehensivelyconsideringfunction alongsideform.
Simplifyingusers’livesbyprioritisingtheirneeds andwantsatarangeofdierentscales.
Strivetousedesignandengineeringasatoolto combatourclimatecrisis.
Naturalleaderbutalsothriveasateamplayerto achievesharedobjectivestogether,whilst stretchingmyknowledgeandcapabilities.
Tools
oSOLIDWORKS(ModellingandVisualisation)
oCSWAMechanicalDesign:IDCCSQ3JR58BA
oCSWASustainableDesign:IDCJA8ELKXZP3
oSIEMENSNX(Modelling,Machining,andVisualisation)
oLuxionKeyShot
oProcreate/AutodeskSketchbook
oCura/PrusaSlicer/BambuStudio
oCloudCompare
oSimaPro
oAnsysGrantaEduPack
oMicrosoftOice/GoogleWorkspace/iWork
oPython(basics)
oAdobeCreativeCloud(basics)
oPenandPaper
AwardsandHonours
2024
2023/24
2020
2020
2024 FutureTalentScholarship InstitutionofEngineeringandTechnology
2020 WolfsonSchoolPresident LoughboroughUniversity
2020 Prospect100forInnovation Prospect100/Oditi
2016 IndustrialCadetsGoldAward EngineeringDevelopmentTrust
Skills
oTeamLeadership
oProjectManagement
oProductDevelopment
oDfM&DfA/DfD
oCAD/Solid&SurfaceModelling
oHands-on/RapidModelling
oMaterialSelection
oProductVisualisation
oFDM3DPrinting
oFiniteElementAnalysis(basics)
oMetrology
oLifeCycleAssessment
oMachineVision(basics)
oGenerativeAIPromptEngineering
oGerman(conversational)
EngineeringLeadersScholarship RoyalAcademyofEngineering
JackPetcheyAchievementAward JackPetcheyFoundation
InnovationandPeople’sChoiceAwards SECBEConstructingExcellence
BrightIdeasNationalWinner Shell
ProductModelling &Rendering Page28
CutleryCleaner Page14
PersonalisedUV ExposureProtection Page10
StudioSeventy FDMSunglasses Page27
Page25
Sketching Page29
Collapsible BicycleTrailer Page5
2025/26WorkinProgress
TeamleaderinuniversitygroupdissertationdevelopingasustainablebusinessclassseatconceptfortheBoeing787,supportedby BritishAirways.
Usingaholisticdesignmethodology,activelyexploringhowstrategicchoicesincluding:theadoptionofadditivemanufacturingfor optimisedframeconstruction,advancedmaterialselection,enhancedmodularity,andinnovativecabinlayout,cansimultaneously meetpresentneeds,guaranteefuturesustainability,andelevatethepremiumpassengerexperience.
2024/25
Individualuniversitydissertationprojectdevelopingacollapsiblebicycletrailerforcargo,supportedbyBromptonBicycleengineers.
Problem
Cyclingisahealthyandsustainablewaytotravel,withtheaveragepersonsaving3.2 kgCO2/daybychoosingabicycleoveracar.However,carsareoftenpreferreddueto theirincreasedcargocarryingcapacity.
Cargobikesandexistingtrailerscanhelp,butthey’reoftenhardtostoreandnotideal formulti-modalcommutes,commonneedsinurbanareasandparticularlyprioritised byBromptonBicycleowners.Howcanwemakecyclingmorepracticalforcitylife?
Oftengets pinch punctures fromtryingto carrycargoin bagson handlebars
Concerned aboutsecurity ofhitchon existing product
Engineering-LedDecisions
Throughoutthedevelopmentofthe product,engineeringprincipleswere constantlyreferredto,ensuring choiceshadcoherentreasoning
Forexample,thesizingofthe standardaluminiumtubingwasbased onanextremeloadingscenarioanda factorofsafetyofapproximately2.
Carries boxes,gas canisters, compost using flaened trailer
Hasn’towneda carin21years andmoved housebybike
Takethelongestframelengthstotake 50kgateachend(sharedequally betweentwolengths:245.25N)when unhitched
12.5%tongueloadshiftingwheel rearwardscausingagreatermoment towardsthefront
Aluminium6061T6withyieldstrength 130MPaallowsforastandardtube sizeof⌀22mmouterand⌀19mm inner
SecuringtheFrame
Thelinkagesareprohibitedtopass90° duetothecarefullyconsidered geometry.Lockingtubesusingspring plungers,atthefrontandrear,further ensuretheframeremainsinthe expandedposition.
Amodularmouldenablesthereartubeto holdarearreflectorattheUKlegalheight of250mmabovetheground.
Multi-PurposeClamps
Aclampwasdesignedtoaachtothetrailer’sframe andsupportthesidepanels.Throughiterations, morefeatureswereadded,includingspacefor ringsanddeflectors.Thepartwascarefullyrefined foreicientinjectionmoulding
IntuitiveAachment
Thetrailer’sdrawbarfeatures aself-lubricatinginsertthat restsatopaballstud,whichis mountedonabentsheetpart fixedtothebicycle’srearaxle, enablingarticulation
Theyellowthroughthecap showswhentheballstudis aligned,withgreenindicating whenthecapissecurely lockedbythespring-loaded pushbuon
Deflectors
AsdescribedinBSEN ,thetrailer requiresadeflectiondevice toensurethatavertical objectdoesnotgetstuckin frontofthewheel.Through incrementaldevelopment, ,aTPUsolution
Versatile Amplecapacitytocarryawide rangeofcargoincludinga foldedBromptonbicycle
Upcycled
Trailersidersandbasemadefrom durablerecoveredtrucktrailer tarps
Lightweight
Aluminiumalloyconstruction enablesaportabletrailerthat feelsweightlesswhenriding
Compatible
Aachestotherear axleofbicyclesecured bytheexistingbolt
Reused Bromptonhingeclamp leverreusedtojoin drawbartoframe
FoldingMechanism
Avarietyofdierentframedesignswere iteratedthroughandmodelledwithcardboard andPVCplumbingpipe.Thesidesandbase collapseusinganorigami-inspiredtechnique.
Designedfor Disassembly
Intheeventofrepairor endoflife,allmaterials canbeseparatedfor easiermanagement
Adaptable
Sidesand/orbasecan beremoved(withhookand-loop/bolts)tosuit users’specificneeds
Repurposed
Bromptonfrontwheels withprovenperformance andreducedwaste
Prototyping
Afunctionalprototypewascreatedto validatecriticaldesignassumptionsand demonstratethefeasibilityofthe engineeringsolution,followingdetailed engineeringdrawings.
Feedback
Userfeedbackandbenchmarkingagainst existingproductswerekeytestingmethods utilised,withBromptondesignand manufacturingengineersalsoproviding insight.
“Thefoldingnatureofthetrailer providesclearvaluetousersin bothtransportationontrain networksandstorageinurban environments…criticaltothecore Bromptonoer.”
“Thomasengagedprofessionally andclearlyindiscussionsincluding analysisonpotentialfurther requireddevelopments,inaspects suchasthespeedoffoldingand thetouchpointdesign.”
FunctionalTesting
Testingincludedestablishingdynamictippingstability(asspecified byBSEN178607:2024,calculatingturningradius,anddetermining brakingdistance.
2024/25
IndividualuniversityconceptualdesignprojectforaproducttoaidinpersonalisedUVprotection.
WilliamJones Name 27 Age
OccupationFinanceAssociate
Income£2,393permonth
Workslonghoursanddoesn’thavea lotoftimeforself-care.
Hasafamilyhistoryofmelanomaand anxiousaboutdevelopingithimself.
Lovestheoutdoors,butwearythathe cannotstayoutforlong.
NamesTallulah&JosephTimber
33&34 Ages
OccupationsMarketingManager&SoftwareEngineer
Household£5,167permonth Income
Health-conscious
Risk-aware
Outdoorsy
Responsible Mindful
Proactive Busy
Allhavedierentskintoneswith dierentneeds.
Anxiousaboutapplyingsunscreenas theybelieveitwillblockVitaminD.
Theirchildhaseczemathatneedsto beconsideredwhenusingsunscreen.
Protective
Multitaskers
Time-pressed
Aentive
Dependable
Preoccupied “Idon’thave
Caught-up
Diverse
Balancing
Patchyawareness
SLANTEDFOR BETTERVISION
IFPLACEDON TABLEAND SEENFROM ABOVE
MAYNEEDMORE SYMBOLS INSTEADOFTEXT
COULDBEWALL MOUNTED
DOUBLESASA TEMPERATURE /WEATHER INDICATOR
SCREENINSPIREDBY ELECTRONICSHELFDISPLAYS, USINGE-PAPER/LCDINSTEAD OFRGBDISPLAYS
CARTRIDGEFROM THETOPWITH SUNSCREEN INGREDIENTS
BUTTONSTO SELECT
DIFFERENTUSER PROFILES
Intuitive
Theraisedribsactasanaordance withaslightsignifierwithdecreasing widthsmakinganarrowheadshape.
Comfortable
11°viewingangletoallowfor comfortableoperation
Choice
Usercanchoose betweenaflowcap, roll-onorspraywhen applyingsunscreen frombole
Individual Forfamilyapplications, dierentcolourlids correspondtodierent userformulations
AlwaysEnough
Transparenttoseehowmuch sunscreenisleftwhenonthego
SETUP
Usingthecompanionapp,the userscanstheirskinusing machinevisionandMonkSkin ToneScale(promptedevery3 months)andselectsanyskin conditionsfortheirprofile
DISPENSE
Theusercannavigatetotheir ownprofileanddispensetheir customsunscreenformulainto theirhandfortheirskinneeds andthecurrentUVexposure
Theuserfillscartridgeswithothe-shelforsundropbranded sunscreenandcomponentsand insertsitafterslidingthelid LOAD
Iftheuserwillbeawayfromthe dispenser,theycanfillupa portablevesselthatcanstoreat least3fullbodysunscreen volumes
REMIND
Theuserispromptedbyaphone notificationorbyglancingatthe displayiftheUVindexisabove3 inthelocation
READY
Whenneeded,theusercanapply andreapplywiththeportable vesselsandcanchoosetobe promptedusingaphone notification
Connectingto internetforMet OiceUVIndex& temperature,and synchronisation withuserprofile Cycles around withno input
[dispense] [nextuser] Visualquick confirmation ofinput
2023/24
Teamleaderandleaddesignengineerinuniversityprojectexploringcutlerywashing,supportedbySagentiaInnovation.
44%ofUKhomeshavedishwashers,butcost orpracticalityhinderothers.Amidbusylives,thereis arisingdemandforinnovativeproductstomanage sinkpile-ups
Prototyping
SpiralDriveMechanism
InspiredbytheYulaspinningtop andOXOGoodGripsSaladSpinner, Iexploredspiral-drivemechanisms usingpatentsandproduct teardowns.
Themechanismdrivesascrew throughatoothednut,which engageswithacentralcolumnto rotatethebristles.Rotationwas limitedtoanti-clockwise(though bi-directionalmotionmayhave improvedcoverage).
Materials
MaterialswereselectedusingAnsysGrantaEduPack, consideringperformanceinwetenvironments,durability,and manufacturingsuitability:
oPolycarbonate(Copolymer,HeatResistant)forthebody: impact-resistant,UVandtemperaturestable,injection mouldable,andeasytoclean.
oStainlessSteel(Austenitic,AISI304forthescrew,nut,and spring:corrosion-resistant,hightensilestrength,andfatigue resistant.
oTPU(Polyether,ShoreA70forthebuongripandfeet:water andchemicalresistant,durable,andwear-resistantwith goodtemperaturestability.
oPolyamide(Nylon,612forthebristles:flexible,fatigueresistant,lowmoistureabsorption,andthermallystable.
Repairable Mechanismcanbe disassembledto replacecomponents ifneeded
Designedfor Manufacture
Radiicarefully consideredfor injection moulding
Rotation
Teethtoensure bristlerotation inonedirection (anti-clockwise)
DryingandAccess
Thecutleryholdercanbetaken outforairdryingandeasyaccess atmealtimewithanintegratedflip downhandle
Stability
TPUfeetto keepcutlery holderin place
Comfort
TPUcoverforincreased usercomfortwithan interferencefit,keeping thescrewinplace
Snap-fitCollar Ensuresthebuon staysinplace
Spring Returnsbuonto equilibriumposition
Replaceable Screwtoenable bristle replacement
Hygienic Turbulentflowof waterremoves foodfromcutlery
Mesh
Waterandfood passthrough
2021/22&2024
YearlonginternshipandsummerinternshipatadditiveanddistributedmanufacturingstartupBatch.Works.
Background
Afterfinishingschool,Itookagapyeartogainindustrialexperiencebeforeuniversity, interningforayearatadditivemanufacturingstartupBatch.Works.Ireturnedfora summerinternshipaftermysecondyearatuniversity.
Duringbothinternships,Iheldsignificantresponsibilitiesindesign,production,andR&D, workingonprojectswithclientssuchas: anddozensmore…
Duetocompanyconfidentiality,Ihaveomiedsomeofmywork.
ReducingPrintTimes
Batch.Worksprimarilyproduces productsusingFusedDeposition ModellingFDMwithlargenozzle diameters,singlethickwalls,andthick layerheights.
Myresearchintooptimisingprinting parametersachieveda45.8%reduction inprinttimesforaproductcollection, whilstensuringconsistentquality acrosstheprinterfleet.
Automation
Iimplementedamethodusingthe extruderheadtoknockofinished productsintoatrayafterturningothe heatedbed,followedbynozzlecleaning andstartingthenextprint.This increasedmachineutilisationand overnightthroughput.
Bene
OicefurniturecompanyBenewereinterestedinlaunchinganaccessoryrange designedPearsonLloyddesignstudio.Batch.Worksassistedwithdesignand manufacturedthecollectionsforindividualandbusinessuse,withtheadoptionof circulareconomyprinciplesandmadefromrecycledPLA.
Iwasheavilyinvolvedwiththedesignformanufacture,development,andproduction ofthebFriendsrange.
Featuredin:
DesignforAdditiveManufacturing
Aspecificexampleofmyinputwasonthecableandtidyboxes,whereIadvised PearsonLloydonedgegeometryandcurvaturetooptimiseforconsistentproducts.I refinedthetop-edgedesignandadjustedthefinal-layerextrusiontoachieveareliable transitionfit,usingalogical,recordedprocess.
Materials
ItravelledtotheAmsterdamfactoryfourtimes(whichwassharedwiththematerial supplier),whereIgainedahands-onexperienceinturningrecycledPLAandPETG pelletsintofilament.However,impuritiesintherecycledcontentandmaingagent occasionallyaectedfilamentquality,whichItackledwithresearchtocompensatefor alteredmaterialflowrates
Engraving&ProductionTools
Mostproductswereengravedwiththeclient’slogoandResinIdentificationCode RIC.Idesignedphysicaljigstoorientproducts,developedphysicalanddigital productiontools,andintroducedStandardOperatingProceduresSOPs),suchas consistentz-heightprintoset,toensureuniformityacrossproductionbatchesand locations.
2023
SummerinternshipatLoughboroughUniversity’sIntelligentAutomationCentreresearchingfringeprojection3Dscanningand collaborativerobots.
SurfaceDefectDetectionwithToyota
AttheIntelligentAutomationCentre,IworkedwithToyotaMotorManufacturingUKtoexploreFringe Projection3DScanningasamodernalternativetotheirmanualvehiclesurfaceinspectionmethod.
IhelpedtestthetechniqueonaToyotaRAV4fender,generatingdetailed3Dmodels900,000–1,100,000points)frombothEDcoatedandbaresteelsurfaces.ThescanswerealignedusingIterative ClosestPointICP,andthefindings,demonstratingthemethod’sreliabilityacrosssurfacetypes Dentsandbumps(~1mmto~5mmindiameter)werecreatedtosimulatedefects.Using CloudCompare,Ialignedscansandidentifieddeviations>1.5mm.Resultswereconsistentacross surfaceswithsharedwithToyotainatechnicalreportandlivedemonstration.
Non-ContactGolfClubAngleDetectionforPING
PINGalsoapproachedtheresearchcentre,andIexploredanoncontactmethodformeasuringloftandlieanglesofgolfclubsfor manufacturingqualitycontrol
ScanswereprocessedinCloudCompare,usingRANSACtofit planesandcylinderstoclubfeatures.Whilethemethod successfullydetectedkeygeometry,randomsamplingledtominor inconsistenciesinresults.Futureimprovementswereproposed, includingfull-segmentfiingforbeerrepeatability.
Low-CostCobotIntegrated3DScanning
ExperimentswithToyotaandPINGdemonstratedthepotentialofnon-contactopticalmeasurementinvariousapplications.Akeychallengeiscapturingacompletepointcloudfrom multipleangles.Whileturntablesarelimited,cobots(collaborativerobots)oeraflexiblesolutionforrepositioningthescanner.
However,thehighcostof3Dscanningandroboticslimitsadoption,withexistingsystemsoftenpricedinthesix-to-sevenfigurerange.Thisprojectaimedtodevelopalow-cost,portable scanningsystembyintegratingalightweightfringeprojectionsystemwithasix-degrees-of-freedomroboticarmandaPC.
igusReBeL
~£5,750
Trolley
~£800
2xBasleracA244035uccameraswith 12mm1:2.82/3” lenses
~£1,500
YuafeyPicoMini ProjectorFOFO ContrastRatio: 2000:1,Brightness 120Lumens)
~£150
Duetorepeatabilityissue,thelowercostsolutionwiththeigusReBeLdidnotproceed;however,theInovocobotsolutionseemedpromising.Thescanbelowconsistsof898,682points, stitching45scanstogetheratapproximately0.3secondsperscan.Theaveragepoint-to-pointdistancewas0.622mm
VDI/VDE2634Evaluation
TheInovocobotsystem’saccuracyandprecisionwasfurtherexploredwithtwoexperimentsIdesignedbasedontheVDI/VDE2634standard.Usingacalibratedballbar(sphere-tospheredistance-300.149mm),thescannertook700scans(usingtwodierentmethods)andmeasuredthemeancentre-to-centredistanceofthespheresusingRANSAC.
Scannertakes100 scansconsecutively
Cobotmovesscan tonewpositionand takes100scans consecutively
Processrepeated until7positionsare reached
DistanceMean CalibratedDistance
3DMetrologyConference
DistanceMean CalibratedDistance
Scannertakes1scan
Cobotmoves scannertonew positionandscanner takes1scan
Cobotmovesto7 positionsbefore returningtoinitial
Processrepeated until100scansare takenateach position
Ourprojectwasselectedaspartoftheposter exhibitionatthe3DMetrologyConferenceheldin Bilbao,Spain.Ourfindingswereshowcasedtothelikes ofAirbus,NationalPhysicalLaboratoryNPL,and Physikalisch-TechnischeBundesanstaltPTB.Italso servedasagreatlearningexperiencespeakingto othersabouttheirwork.
Someoverlapforadhesionbetween adjacentextrusionstoincrease rigidity
Doubleinnerhexagonwalltoensure wallsremainfixedandthetorque wrenchdoesn’tslip
Designextension: removingevery otherlayerofthe secondarywallto reduceweight
Supportto midpointof inner hexagonwall propagated outwards
Nozzle:210°C
Bed:60°C
Height:0.20mm
TeamleaderandleaddesignengineerinuniversityprojectmanipulatingFDMprintpaths usingFullControlXYZforahexnutthatwithstoodatrequiredminimum1.75Nmoftorque withthelowestpossiblemass.Mydesignuniquelyexploitedalternatingeveryotherlayer.
ExtrusionWidth:0.45mm
Designextension: Reducing extrusionwidthto 0.4mm
Triangle shapeproved strongest fromourinitial experiments
Adhesionwherethe extrusionwidthscross over
948mgmass 1.90Nmtorquebeforefailure
Failurecausedby fractureincornerof innerhexagon
Asliletravelusedas possibletoreduce overallprinttime
Designextension: enabling retractionto reducestringing
Alternatinglayersresultin significantreductionofweight optimisingdesignforaerospace
Symmetricalallowingfor consistencythroughoutthepart
TeamuniversityprojectmodifyingabasicversionofMinesweeper usingPython,bydevelopinganewGUI.Theprojectinvolved creatingaUMLandapplyingthegoldenrulesofGUIdesign.
FusedDepositionModelledFDMsunglassesforfashion brandStudioSeventydesignedandmanufacturedby myselfwhilstinterningatBatch.Works.
HolePunch
ModelledinSiemensNX
RenderedinSiemensNXRayTracedStudio
OXOCanOpener
ModelledinSOLIDWORKS
RenderedinKeyShot
FairyWashing-upLiquidBole
ModelledinSiemensNX
RenderedinKeyShot
Ideationphaseforaproductthatcollectshairintheshower Annotationshavebeenremoved.
Refinementphaseafterprovingconceptswithphysicalmodelsandfurtherresearch Annotationshavebeenremoved.
UPSKILLING
FITNESS
TRAVELLING
NATURE
tommgbor@gmail.com
@thomasm.design
/in/thomas-mgbor/ www.thomasm.design