TOOHEY
Mechanical Engineering & Computer Science Graduate with hands-on industry experience in product development, 3D scanning, CNC design, and custom manufacturing for the 4WD aftermarket sector.
Independantly led end-to-end design of three Venturer steel bullbars across distinct vehicle platforms, taking each from initial 3D scan through to offshore production release. Captured precise vehicle geometry using Artec Studio, developed full sheet metal assemblies in SolidWorks, and managed prototype fitment testing on real vehicles to validate tolerances and compliance. Airbag compatibility added a significant layer of complexity to each design, requiring collaboration with senior engineers to validate deformation behaviour through pendulum impact testing and FEA, ensuring the bullbar structure would not interfere with safe airbag deployment.
Designed and developed two custom sheet metal modules for TJM's 50th anniversary 105 Series Land Cruiser, debuted at the Brisbane 4WD Show. Each module required seamless structural integration with the existing MSA drawer system, supporting significant component loads including a twin-cylinder compressor, while packaging all electrical and air components cleanly within the gullwing door envelope. With minimal existing vehicle data and a hard show deadline, the work required rapid reverse engineering of available geometry to produce structurally sound, fitted parts under serious time pressure. Every stage of the design was owned independently, from first measurements to final fitment.
Designed a CNC-machined aluminium insert enabling standard recovery points to be adapted for use with soft shackles, now sold as a production TJM product. The part required careful attention to geometry to avoid stress concentrating on the shackle webbing, ensuring the insert did not reduce the breaking strength of the shackle compared to a direct soft shackle recovery point. Static load testing was conducted to soft shackle failure to validate the design, confirming the insert could withstand forces beyond the shackle's breaking strength.
Designed and developed a modular, ergonomic underwater toolbox to improve the efficiency and scalability of coral reef restoration diving, addressing a real operational problem as global restoration efforts scale to meet increasingly ambitious targets. User-centred research was conducted with five experienced restoration divers through interviews and pre-interview forms, identifying key pain points including dropped tools, poor organisation, and excessive drag. Multiple design iterations were developed using a 2020 T-slot aluminium frame with PETG 3D printed components, progressing from a crate-inspired concept to a compact drawer-based system based on diver feedback. Overall assessment scores improved from 3.3 to 4.7 out of 5 between versions, with tool management and safety ratings both rising from 3.3 to 4.8. Buoyancy testing validated the prototype for real-world use, with field deployment during active restoration dives in Malaysia scheduled for mid June 2026.
Mar 2022 — Present
Brisbane, QLD
- Independently developed new 4WD accessories — CAD models, design iterations, and technical drawings in SolidWorks — supporting the timely release of multiple products.
- Used 3D scanning (Artec Studio) to capture vehicle geometry and process mesh data for reverse engineering and custom part design.
- Designed CNC-machined aluminium components and complex sheet metal assemblies, applying tolerancing and surface finish requirements for production-ready parts.
- Built an internal Python application to automate prototype drawing file management, reducing a multi-hour manual process to under 5 minutes — saving an estimated 500+ hours annually.
- Managed CAD data in PDM Vault, maintaining version control and file referencing integrity across design teams.
Aug 2021 — Present
Brisbane, QLD
- Founded and operated a small business producing custom 3D-printed products for the aftermarket 4WD industry, managing the full product lifecycle independently.
- Developed deep technical knowledge of FDM materials — PETG, ASA, ABS, and carbon-filled composites — optimising for mechanical performance, durability, and environmental resistance.
- Tuned slicing settings and print profiles to balance mechanical performance, dimensional accuracy, and print efficiency across varied geometries and load cases.
A dual degree combining mechanical engineering with computer science, covering mechanical design, analysis, and simulation alongside programming, software engineering, and IT project delivery. Skills from both streams have been applied directly throughout industry roles.
Operating at the intersection of mechanical design and software: able to build the part and write the tool that automates the workflow around it. Hands-on background in 3D Printing, sheet metal, CNC design, and 3D scanning.
Equally comfortable working independently or as part of a team, with the drive to research problems thoroughly and make informed decisions before consulting senior engineers to validate the approach. Deadlines are a motivator rather than a stressor, as demonstrated delivering a complex show build under a hard exhibition deadline, and the ability to work efficiently under pressure is something that comes naturally.
Beyond the technical, the goal is always to be someone who makes the workplace better to be in: approachable, upbeat, and easy to work with. Engineering is a collaborative discipline and the belief is that a good team culture produces better outcomes than technical skill alone.
Open to mechanical engineer roles in Brisbane. Particularly interested in opportunities spanning the full development cycle, from concept through to production release. Happy to discuss opportunities across product development, design for manufacture, or hands-on engineering work.
Open to opportunities
