Steve Hammond
I help teams turn incomplete ideas into products that can be built, tested and supported. My work connects mechanical design, analysis, suppliers, production and the software that keeps engineering moving.
Selected work
Selected projects ordered by scale, technical ambition and the breadth of the problem solved.
Packaging batteries, drivetrain, high-voltage wiring, sensors and computing into complete vehicles, while resolving clashes and build risks.
Cooling architectures, manifolds, battery structures and HVAC developed from early concepts through supplier-aligned production release.
SQL and web tools, CAD approvals, BOMs, version control and engineering-change workflows that keep distributed teams aligned.
Quoting, scheduling, job management, remote monitoring and inspection workflows connected directly to physical production.
The fully autonomous halo car for the world’s first autonomous racing series, developed without space for a human driver.
A Ginetta prototype transformed into an autonomous racing test vehicle and brought to the track in four months.
Thermal hardware and controlled engineering workflows developed together for a planned run of 499 electric vehicles.
Battery cooling architecture for repurposed electric vehicles operating in Dubai temperatures.
Compact 40 bhp Wankel engines developed for demanding UAV, hybrid and specialist vehicle applications.
A 22-machine print farm and web-based production system linking orders, scheduling, materials and inspection.
A custom-fit respirator system connecting phone-based face scanning to digital fitting and on-demand manufacture.
Experience
From early concepts and analysis through drawings, suppliers, test and production release.
Full experience in my CV2025–now
Independent Engineering Expert
Industrial design and mechanical engineering expertise for model evaluation and improvement.2025
Thermal Systems Architect and Advisor
Battery cooling architecture for a Dubai-market EV platform and UNECE R100 requirements.2021–2024
Principal Thermal Systems Engineer
Production-ready cooling, air-conditioning and battery structures for a low-volume electric vehicle.2023–2024
Senior Mechanical Design Engineer
Air-cooled 225ACS SPARCS rotary engine concept developed to Preliminary Design Review readiness.AIE 225ACS2018–2021
Co-founder and CTO
Additive manufacturing, medical products and connected production systems.2016–2018
Mechanical Design, BOM and Project Engineering
Autonomous vehicle integration, distributed CAD and web-based PDM.1999–2018
Aerospace, UAVs, rotary engines, offshore systems, specialist vehicles and production machinery.
Capabilities
Concepts, prototypes, design reviews, testing and production release.
Assemblies, structures, thermal systems, packaging, sealing and tolerance design.
FEA, CFD, hand calculations, optimisation and evidence-led design decisions.
Machining, sheet metal, tubes, welding, moulding, composites and additive production.
BS 8888, ISO GPS, GD&T, BOMs, PDM and engineering change control.
Web tools, SQL, production workflows and automation that connect engineering work.
Tools NX · SolidWorks · Solid Edge · Inventor · Onshape · Ansys · MATLAB · Mathcad
About
I am most useful when a design is incomplete, the interfaces are messy and someone needs to connect CAD, analysis, suppliers, testing and production.
Over more than 20 years, I have worked across electric and autonomous vehicles, aerospace, rotary engines, manufacturing automation and medical products. The common thread is practical systems thinking: finding the hidden dependencies and turning them into something a team can build and support.
BEng (Hons), Integrated Engineering with Automotive Studies, Sheffield Hallam University.
Get in touch
Tell me what is stuck, incomplete or proving harder than expected.