21.10.2026 aktualisiert

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Multidisciplinary Engineering Technical Lead – Automation, Controls & Advanced Manufacturing

Hamburg, Deutschland
Nur Remote
BEng Mechanical Engineering, First Class Honours, Manchester Metropolitan University, June 2015
Hamburg, Deutschland
Nur Remote
BEng Mechanical Engineering, First Class Honours, Manchester Metropolitan University, June 2015

Profilanlagen

Tom-Forshaw-two-page-CV-26-1.pdf

Über mich

Multidisziplinärer Ingenieur und technischer Leiter mit über 20 Jahren Erfahrung in Konstruktion, SolidWorks, FEA, Automatisierung, Siemens TIA Portal, WinCC, SCADA, SPS-Programmierung und Inbetriebnahme. Praxisnah, lösungsorientiert und hands-on. Entwickle robuste Lösungen für technische Aufgaben.

Skills

ModbusProfinetSIMATIC WinccCAN FDTia PortalSps-software
Industrial Automation & PLC Controls
Expertise in TIA Portal / STEP 7, CODESYS / IEC 61131-3, WinCC / SCADA, Node-RED, Profinet / Profibus / OPC UA, machine safety, Siemens and SEW motion systems, AGVs and autonomous navigation, as well as VirtualBox / VMware. Extensive hands-on experience designing, commissioning and optimising large-scale automated systems in aerospace and automotive environments.

Mechanical Design & CAD Engineering
Proficiency in SolidWorks and CATIA, including FEA and simulation, complex assemblies and components, DFM, CNC machining and 3D printing. Proven track record delivering parametric product-configuration systems, manufacturing drawings and BOMs from customer dimensions.

Embedded Systems & Electronics
Hands-on capability with PIC and ESP32 microcontrollers, embedded C/C++, ESP-IDF, Python, PCB design in KiCad, analogue electronics and OTA systems. Demonstrated ability to take custom electronics from circuit design through manufacture, assembly and calibration.

Measurement & Metrology
Laser tracker metrology, load cells, calibration, LabVIEW / DAQ and automated test rigs. Experience transforming multi-day metrology processes into rapid automated operations using laser trackers, best-fit measurement and servo positioning.

Systems Architecture & Technical Leadership
System-level architecture definition covering industrial automation, PLC/HMI, distributed I/O, safety, hardware selection, software structure and data exchange. Led cross-European technical reviews and consolidated lessons from major A320/A350 projects.

Machine Vision & Precision Motion Control
Integration of machine vision with precision hexapod positioning and Siemens S7-1500 control for automated wing-assembly R&D systems. Development of real-time position acquisition and precision motion control communications.

Aerospace Systems Engineering
System-level integration, interface-conformance testing, ground and range trials, certification and technical documentation across Eurofighter Typhoon, A319/A320/A321 and spacecraft mechanism programmes.

Engineering Practice & Safety
Technical Leadership, Systems Architecture, Safety / FMEA, Commissioning, Documentation, Root-Cause Analysis and Jira / Confluence.

Erfahrung

Berufserfahrungmehr als 10 Jahre
Freelancer seit2026

Sprachen

DeutschGrundkenntnisseEnglischMuttersprache

Projekthistorie

Research & Development

Independent Product Development
Self-funded multidisciplinary research project spanning mechanical design, electronics, embedded firmware, PLC control and test automation. Built bench rigs to characterise load-cell ADC front ends, designed and prototyped mechanical parts in SolidWorks with FEA validation, generated CNC toolpaths and machined components, and designed circuits and PCBs in KiCad including instrumentation amplifiers, power and interface hardware.

Technical Lead – Auto-Rigging & Automated Aircraft Assembly

Airbus
Led controls and integration architecture for an automated wing-assembly R&D system combining machine vision, precision hexapod positioning, Siemens S7-1500 control, safety systems and industrial HMI. Defined the industrial automation architecture including PLC/HMI, distributed I/O, safety, hardware selection and software structure. Worked with the hexapod manufacturer to develop S7-1500 communications for real-time position acquisition and precision motion control. Led cross-European technical reviews of auto-rigging and automated-assembly R&D across sites in Germany, France, Spain and the UK.

Company Founder

S7 Systems
Industrial automation, controls engineering and commissioning consultancy for aerospace and automotive manufacturing. Provided PLC/controls consultancy and production support for the Airbus A320 4th Final Assembly Line. Developed a PLC simulation platform for offline PLC code development using Node-RED and a Siemens S120 servo test bench. Commissioned large-scale VW ID.4 conveyor/material-handling systems in Emden to the VASS standard. Developed a reusable PLC library for low-voltage conveyor controllers and commissioned automated wheel handling and the complete line-delivery system at Volkswagen.

Controls, Integration & Commissioning Engineer

Nova-Tech Engineering
Developed and commissioned major parts of the automated process flow for loading, transporting, positioning, aligning and unloading A319/A320/A321 aircraft sections across 10 mobile tool platforms, spanning PLC/HMI, motion, metrology, navigation and safety. Developed controls architecture for automated A320/A321 forward-fuselage assembly integrating servo-controlled positioning with laser trackers. Reduced a critical automated process from 9-11 hours to 15 minutes by developing an eight-axis load-balancing system.

Company Founder

Atom Engineering & Design
Mechanical design, CAD automation and engineering consultancy supporting specialist product development and manufacturing. Introduced waterjet cutting for aluminium-honeycomb components, reverse-engineered a specialist product range into a fully parametric SolidWorks system, and delivered detailed design engineering for a specialist fit-out project converting architectural GA data into SolidWorks assemblies and manufacturing drawings.

Systems Engineer – Eurofighter Systems Integration

BAE Systems
Supported system-level integration, interface-conformance testing and ground/range trials of aircraft role equipment. Acted as technical authority for new-technology and customer trials and demonstrations, and provided technical support to Final Assembly. Produced and reviewed conformity, certification, trial and technical documentation for Typhoon production/development aircraft.

Systems Engineer – Assembly, Integration & Test

ESR Technology
Designed, built and commissioned spacecraft-mechanism test rigs from requirements through SolidWorks/FEA, drawings, supplier manufacture, instrumentation and laboratory commissioning. Prepared and operated high-vacuum test environments and built a Kistler load-cell amplifier-to-LabVIEW interface to automate load and torque testing. Developed test fixtures and supported mechanical design/FEA for a spacecraft cup-and-cone separation mechanism.

Aircraft Fitter – Superplastic Forming

BAE Systems
Operated and set up large-scale SPF equipment, monitored high-temperature/high-pressure processes and supported thermocouple calibration, inspection and traceability. Supported commissioning/testing of a new PLC-controlled automated SPF facility.

Advanced Apprenticeship

BAE Systems
Awarded BAE Systems Apprentice of the Year after independently developing and presenting a working R&D technology demonstrator. Selected for an extended FLAVIIR R&D placement with Cranfield University, manufacturing a low-tooling titanium thrust-vectoring exhaust structure and supporting electrical integration and commissioning of the experimental aircraft.

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