Lucas Ferreira
Mechanical Engineer, P.E. — Product Design & Manufacturing
lucas.ferreira@email.com · +1 (734) 555-0166 · Ann Arbor, MI · linkedin.com/in/lucasferreira
Summary
Mechanical engineer with 7 years designing electromechanical products from concept through high-volume production. Led the mechanical design of a battery-powered tool line now shipping 180K units a year, cut per-unit cost 14% through design-for-manufacturing changes, and hold 2 patents. Licensed P.E. in Michigan.
Experience
Senior Mechanical Engineer — Huron Power Tools, Ann Arbor, MI
Jan 2021 – Present
- Led mechanical design for a 3-product cordless tool line (housings, gear trains, thermal management) from concept to production; 180K units shipped in 2025 with a field-failure rate under 0.4%
- Reduced per-unit cost 14% ($2.1M a year) through DFM changes: consolidated 11 machined parts into 4 die-cast components and re-specified fasteners
- Ran FEA and thermal simulation in ANSYS to cut prototype iterations from 5 to 2 per component
- Own supplier qualification for die-cast and injection-molded parts across 4 vendors in Mexico and Michigan; hold 2 granted patents on the tool’s vibration-damping handle
Mechanical Engineer — Great Lakes Automation, Detroit, MI
Jun 2018 – Dec 2020
- Designed fixtures, end-of-arm tooling and conveyor components for automotive assembly cells; delivered 30+ tooling packages with GD&T-compliant drawings
- Redesigned a pneumatic clamp assembly that cut cycle time 8% on a line producing 1,200 parts a shift
Education
B.S.E. Mechanical Engineering, University of Michigan, Ann Arbor, MI · 2014 – 2018 · Magna cum laude
Skills
Engineering: Product design, DFM / DFA, GD&T, Tolerance analysis, FEA & thermal simulation, Injection molding & die casting, Supplier qualification
Tools: SolidWorks, Creo, ANSYS, MATLAB, Windchill, Minitab
Certifications
- Professional Engineer (P.E.), Michigan — Michigan Board of Professional Engineers, 2023
- Certified SolidWorks Professional (CSWP) — Dassault Systèmes, 2019




