Christchurch
SmartCAD: Precision Engineering by
Martin Mudry MEngNZ
MECHANICAL DESIGN ENGINEER
PRODUCT DEVELOPMENT ENGINEER
I launched SmartCAD in November 2021 to offer expert CAD services for freelance and contract work - turning design concepts into practical, precision-driven results.
Behind every great product is a great idea. Let's work together to make yours a reality.
From early-stage startups with bold ideas to established companies pushing for innovation, I offer flexible design and development support tailored to your needs. Whether you're expanding a product line or racing against a deadline, I use a proven Engineering Roadmap to ensure every project stays on track:
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Define & Analyse: We review your concept together, identify constraints and technical requirements, and create a clear path forward.
- Goal: A clear path from idea to reality.
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Design & Optimise: I develop precision 3D CAD models focusing on DFM/DFA to minimise tooling costs and ensure optimal performance.
- Goal: A validated, production-ready design
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Test & Deliver: I manage prototyping and manufacturing integration to deliver a functional, production-ready product.
- Goal: Successful delivery of a functional product
If this seems like what you have been looking for, do not hesitate to reach out.
I bring a solid set of strengths to the table - technical, practical, and grounded in real-world engineering. From tackling complex design challenges to delivering complete product development solutions, I offer the expertise and problem-solving mindset to drive projects forward. Here's what I specialise in:
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Creative, practical problem-solving
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Strong technical troubleshooting
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End-to-end product design (DFM & DFA)
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Expert in mechanical design and assemblies
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Proficient in CAD/CAM, 3D modelling, and documentation
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Design for machining, injection moulding and metal sheet fabrication
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Rapid prototyping and iterative development
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Testing rig design, hands-on testing, and reporting
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Product enhancement and optimisation
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Reverse engineering legacy parts and systems
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CNC machining and manufacturing integration
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Applying engineering principles to complex problems
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Delivering optimised products on tight deadlines
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Effective client and manufacturer collaboration
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Balancing aesthetics, usability, and manufacturability
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Continuous learning and experimentation
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Innovation in new and existing products
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Precision and creativity in real-world projects
Testimonial
A great partner for our business
"We worked with SmartCAD on our recent NFC Tag updates. We had done the designs for our initial tags in-house, which we used to validate the market, and we brought SmartCAD into design, test and resolve our gen2 tag designs with our manufacturing partners.
Our product range includes a range of production processes and finished goods. We have injection moulded components, laminate & die-cut solutions, enclosures for electronics with impact strength requirements, adhesive specifications and many attributes which required designing for, testing across different materials and finally, goods in testing for consistency.
SmartCAD was a great partner for this processes, with a practical approach to designing, sampling, testing and manufacturing stages."
Flying Wing UAV
Business Class Aircraft Seating Units
As part of my transition toward Aerospace Engineering, I undertook the Aerodynamics and Ground Vehicle Dynamics course at the University of Canterbury. For the course, I selected a self-directed project, the design and development of a flying-wing UAV. Over an intensive ten-week period, I applied aerodynamic theory and course principles to design, build, and test a functional flying-wing drone.
The project involved rapid iteration, extensive workshop time, and hands-on problem solving across design, fabrication, and assembly. This approach allowed me to quickly develop new skills and translate theory into practice through continuous experimentation and refinement. I successfully brought the UAV to the test phase within the course timeframe; however, the schedule limited further testing and performance optimisation.
A team from SJB Consulting reached out seeking support for a project in the aviation industry. They faced a critical certification deadline and needed to accelerate the development process. I stepped in to help create production-ready 3D CAD models and prepare detailed drawing documentation in SolidWorks for aluminium fabricated components and multi-level assemblies.
Beyond these tasks, our main focus was to develop innovative, production-ready solutions that optimised structural integrity, reduced weight, and maximised space utilisation. All while maintaining strict adherence to Design for Manufacturing (DFM) and Design for Assembly (DFA) principles.
Working closely with the team, we successfully met the deadline and finalised the project for production release.
My natural curiosity sparked the idea to develop a completely new wind turbine design. I began with a simple 2D simulation that validated the initial concept, though I knew real-world conditions could differ significantly. To test it further, I built a basic proof-of-concept prototype - and it worked. This success motivated me to invest more time and resources into R&D, refining the turbine's main body shape and developing a fully functional prototype. Despite scepticism from others, the design exceeded expectations in real conditions, successfully generating its first watts of electricity from wind.
The first-generation tag, launched by the customer, successfully sparked interest in the product and brand but revealed a clear need for improvement. The customer approached me to redesign the tag. I immediately saw a clear opportunity to make it smaller, more reliable, and visually appealing. Taking on this challenge, I balanced enhanced performance with cost efficiency, successfully delivering a superior product that exceeded expectations and strengthened the company's market position. What began as a retrofit product is now in high demand among carabiner manufacturers worldwide. As a bonus, thanks to a minor design tweak, we achieved a 58% reduction in initial tooling costs, while delivering two distinct products from a single moulding tool.
When the customer asked me to add NFC tags to round bar carabiners, without using adhesives, it sparked a unique opportunity for innovation. At the time, nothing like this was available on the market, so I quickly developed several creative solutions and tested them using 3D-printed prototypes. What seemed straightforward soon revealed complexities due to specific product conditions and manufacturing limitations. The design was initially rejected by three different manufacturers. Nevertheless, through innovative problem-solving and close collaboration with manufacturers, we overcame every hurdle and got back on track. Currently, the NFC grommet is in full serial production and is going through the patent process.
Motivated by a passion for innovation and to push the boundaries of the turbine's performance, I dove deeper into research to identify additional areas for improvement. To take my idea to the next level, I focused on designing the impeller fan with enhanced performance in mind. By blending product design with CFD simulations and optimisation techniques, I achieved a 120% performance boost in the wind turbine. Facing manufacturing constraints, I adapted the design from a single-piece component to a modular assembly, increasing complexity but significantly improving manufacturability and production costs. This process sparked several breakthrough moments, highlighting my ability to innovate and solve complex engineering challenges.
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After graduating from university, I joined one of the world's largest automotive suppliers, specialising in the design and development of car interiors. I secured a role in the Door Panels department and quickly got involved in the Mercedes G-Wagon project. With tight deadlines, we skipped prototyping and moved straight into the serial production phase. Our team of six divided responsibilities, each handling a different part of the panel assembly. Along the way, we tackled several design-for-manufacturing challenges, but through collaboration and persistence, we met every deadline on time. The project culminated successfully when the first G-Wagons rolled off the production line in 2019.
Ingenuity is at the forefront of everything I do. When I was running low on resources to continue my postgraduate studies, I knew a typical summer job wouldn't be enough. That's when I decided to leverage my skills and my brother's workshop to design, build, and test a bandsaw mill (a machine that cuts logs into lumber using a continuous band blade) with the goal of selling it for profit. For three months, I worked long hours to complete the project before the start of the following semester. I delivered on time, and later that year, with my brother's help, I sold the machine for an impressive 150% profit. This success gave me the confidence and financial boost I needed to continue and complete my master's degree.
The customer brought me a bold idea: to integrate a commercial scanner PCB into a custom scanning tower capable of reading both QR codes and NFC tags, combining two features into one seamless device for easy item pairing. I took on the task of turning this innovative idea into reality by developing the scanning tower and crafting a sleek, functional enclosure for the PCB. By adding a small, thoughtful design detail, I ensured the device was not only highly effective but also visually appealing.
Wood Art Created Using CAD/CAM
Ski Binding Clip - Reverse Engineering
Rope Locker for Carabiners
To design an installation that didn’t need to adhere to traditional mechanical engineering standards? An idea that immediately sparked my interest. A client had a vision-he wanted to recreate the view from his terrace onto a blank outdoor wall. Without a fixed plan for the final result, he gave me complete creative freedom. I embraced the opportunity to step outside conventional design, combining technical skill with artistic intuition. The process involved careful planning, continuous learning, and hands-on experimentation. In the end, the outcome exceeded my expectations-and, most importantly, the client was genuinely impressed.
Some devices and parts may no longer be in production, but there are always enthusiasts who want to keep using them. A friend of mine is passionate about telemark skiing, a style that has largely been replaced by more modern techniques. Finding spare parts for his vintage telemark bindings is nearly impossible today. When his plastic clip broke, he turned to me for a replacement so he could enjoy the rest of the skiing season. This project became a fantastic CAD exercise, but posed a real test for my CNC router. Thanks to a carefully planned toolpath setup, I was able to craft the replacement clips successfully, even using a hobby-grade CNC machine.
What started as a small, enjoyable project for my client quickly evolved into a real product that caught the attention of a carabiner manufacturer. The initial goal was to design a simple component for a carabiner with a locking bar that would allow hikers and climbers to securely attach webbing or cord to backpacks or harnesses. Essentially, it was a reverse engineering challenge: adapting the component to fit the carabiner’s shape within a very limited space. Although the project was small in scope, there were several moments that required me to pause and think creatively to find the right solutions.
Do you have a similar project?
Every project brings me a new opportunity to learn and grow professionally.
From precision mechanical components to innovative design installations, I've developed a strong ability to adapt engineering principles to real-world challenges. Whether working within strict industry standards or exploring unconventional approaches, I combine technical expertise with creative problem-solving to deliver functional, optimised solutions.
My core skills include CAD design, prototyping, CNC machining, and reverse engineering -tools I use to deliver results efficiently, even under tight timelines. I understand the importance of close collaboration with clients and manufacturers in navigating production constraints and maintaining quality.
Continuous learning fuels my curiosity and sharpens my approach to design. It helps me explore new tools, materials, and methods to better balance aesthetics, usability, and manufacturability - whether improving an existing design or developing something entirely new. I thrive on projects that demand both creativity and precision, and I take pride in turning complex ideas into tangible products that create real value.