SEAN KAVAN

Lead Mechanical Designer | Product Development
Sydney, NSW | 📞 0415 994 322 | ✉️ sh.kavan@gmail.com

Professional Summary

Practical, creative mechanical design engineer with 12+ years experience bringing complex products from initial sketch through to full-scale production for diverse sectors. Led mechanical design and modular integration on a $50M rail contract, consistently balancing technical detail, user needs, and real-world constraints. Recognized for rapid concept-to-manufacturing execution, high-impact team leadership, and deep experience in hands-on CAD, FEA, rapid prototyping, and cross-functional project delivery. I thrive on making ideas work for the end user and collaborating with stakeholders to deliver results that last. Delivered multiple projects for both in-house and external clients, achieving accelerated delivery, major cost reductions, and consistent client satisfaction.

Key Skills

Advanced 3D modeling & technical drafting (SolidWorks, Inventor, AutoCAD)
Full lifecycle NPD: concept, prototyping, validation, and production
GD&T, DFM/A, FEA, BOM management, and detailed engineering analysis
Manufacturing methods: injection molding, die casting, extrusion, CNC, sheet metal, springs, gears, GRP, 3D printing
Project management: lean/agile, milestone tracking, risk management
Client-facing consulting, stakeholder management, vendor/supplier engagement
Cross-team leadership, training, and mentoring
Hands-on troubleshooting, root cause analysis, and process improvement
Compliance with ISO 9001/14001 and documentation to regulated standards

Notable Achievements

$50M Rail Contract Leadership
Led mechanical design integration and modular delivery for Perth METRONET contract, delivering DMU toilet/car modules 32 days ahead of schedule while improving system uptime and reducing transport risk.
98% On-Time Project Delivery
Consistently delivered NPD projects on schedule while cutting production failures by 20% and boosting delivery speed by 35% through agile and simulation-driven design methodologies.
30% Cost Reduction Innovation
Achieved zero-defect final products and reduced production costs by 30% through innovative injection mould design and rigorous analysis and testing processes.

Experience

Freelance Mechanical Design & Process Improvement
Sydney, NSW
08/2024 – 05/2025
  • Designed and validated a SaaS MVP for non-technical users (user flow, stack, usability).
  • Led trade feasibility analysis, supplier research, and comparative procurement for construction materials and specialty products.
  • Applied project budgeting, milestone planning, and performance tracking.
  • Streamlined handover processes and training systems using advanced process mapping.
Lead Design Engineer
RPC Technologies
Newcastle, NSW
08/2023 – 08/2024
Leading manufacturer of GRP systems for rail, defence, and infrastructure.
  • Delivered end-to-end production drawings, 3D models, and detailed fabrication packages for modular assemblies used in major rail and infrastructure projects (up to $50M).
  • Led mechanical design integration and modular delivery for $50M Perth METRONET contract (DMU toilet/car modules).
  • Coordinated design, procurement, and production teams to meet accelerated deadlines.
  • Developed flat-pack assembly strategies for logistics efficiency and reduced transport risk.
  • Produced commissioning and maintenance docs to ensure spec/safety compliance.
  • Conducted DFMEA and design validation for system reliability.
Critical Impact:
Delivered METRONET modules 32 days early; improved system uptime and reduced transport risk via design-for-reliability methods.
Lead Design Engineer
Microsystem Controls
Sydney, NSW
04/2019 – 07/2023
MSC is a leading supplier of coin and note validation systems to various industries
  • Led NPD (new product development) projects from initial concept through to implementation, delivering on time, within budget, and to defined scope.
  • Managed regular client meetings to capture requirements and translate feedback into technical solutions.
  • Led and mentored teams of engineers, driving high performance, quality, and a collaborative project culture.
  • Conducted advanced engineering analysis (DFM, FEA, tolerance studies) across multiple high-value projects.
  • Produced technical documentation, feasibility studies, and clear monthly progress reports for clients and stakeholders.
  • Developed and documented comprehensive test plans to meet internal and industry standards.
  • Worked directly with manufacturing teams to optimize factory programs and ensure designs were production-ready.
  • Provided technical guidance and mentoring to design teams throughout the project lifecycle.
Critical Impact:
Consistently delivered 98% on-time NPD projects, cutting production failures by 20% and boosting delivery speed by 35% through agile and simulation-driven design.
Design Engineer
Enviro Building Services
Helensburgh, NSW
05/2016 - 03/2019
  • Conceptualized and designed advanced enclosures for electrical products.
  • Managed prototype development, CFD modeling, and validation testing.
  • Led design and optimization of complex injection molds, reducing costs by 30%.
Critical Impact:
Delivered zero-defect final products by driving rigorous analysis and testing, and reduced production costs by 30% through innovative injection mould design.
Product Engineer/Tooling Design Engineer
Marzban Sanat Co.
Iran
Mar 2011 – Jul 2015
  • Designed injection molds for manufacturing, generated drawings & G-codes.
  • Estimated detailed toolset costs and optimized for efficiency.
  • Created innovative conceptual designs for a fast-paced environment.
  • Produced BOMs and instruction manuals; liaised with manufacturing to improve new products.
  • Supervised engineering teams and guided multiple departments to achieve strong outcomes.
Product Design Engineer
Negahban Fire & Safety Co.
Tehran, Iran
Mar 2009 – Feb 2011
  • Designed a range of firefighting products; prepared manufacturing drawings using SolidWorks.
  • Optimized processes, reduced machining steps, generated BOMs, and provided on-site customer support.
  • Collaborated with retail and sales for customer pricing and project delivery.

Education & Credentials

MEng Mechanical Engineering
University of Wollongong (2018)
BEng Manufacturing Engineering
University of Applied Science, Tehran (2012)
SolidWorks & Inventor Professional Cert | Lean Manufacturing Cert (2021)
Member, Engineers Australia | Chartered status in progress
White Card | Valid Driver's License

Technical Skills & Tools

SolidWorks, Inventor, AutoCAD, GD&T, DFM/A, FEA, BOM management, CFD, injection molding, sheet metal, CNC, rapid prototyping, ERP/MRP systems.