John is available for hire
Hire JohnJohn Carver
Verified Expert in Engineering
Mechanical Engineer and Product and Process Developer
Groningen, Netherlands
Toptal member since September 2, 2026
Bio
John has spent over 20 years building mechanical engineering solutions across consumer electronics, wearables, and healthtech. His toolkit centers on 3D CAD, technical documentation, AI tools, and hands-on prototyping and testing. John has worked on many advanced and demanding projects from inception to deployment, both as an independent contributor and as a team/system lead.
Portfolio
Philips
Nx, Design For Assembly (DFA), Design Failure Mode and Effects Analysis (DFMEA)...
Loop
Product Lifecycle Management (PLM), Windchill PLM, CAD, Manufacturing, Design...
Intel
Geometric Dimensioning & Tolerancing (GD&T), 3D CAD, 3D Printing, Manufacturing...
Experience
- CAD - 20 years
- 3D Printing - 20 years
- Prototyping - 20 years
- Tolerance Analysis - 20 years
- 3D Design - 20 years
- Documentation - 20 years
- Design Failure Mode and Effects Analysis (DFMEA) - 15 years
- Technology - 14 years
Work Experience
Senior Mechanical Design Engineer – Philips Health & Beauty
2025 - PRESENT
Philips
- Led team developing outer shell for premium metal body shaver and associated back attachment/mechanism, managing the technical design transfer from R&D to high-volume manufacturing while ensuring strict adherence to DFA/DFM requirements.
- Drove transition from NX to PTC CREO for the internal team, establishing technical standards and methodologies that increased design efficiency and cross-functional data integrity.
- Provided technical mentorship to other engineers and cross-functional partners, developing a library of CAD standards and training modules, driving best practices across the division.
- Leveraged AI to support cross-functional data and system collaborations. Developed apps via Claude code to enhance decision maturity and efficiency.
Technologies: Nx, Design For Assembly (DFA), Design Failure Mode and Effects Analysis (DFMEA), CAD, Injection Molding, Claude Code, Claude Design, Claude API, Machining, PTC Creo, Windchill PLM, 3D CAD, 3D Design, 3D Printing, ANSYS, Testing, Verification, Innovation, Python
Senior Mechanical Design Engineer – Loop Earplugs
2024 - 2025
Loop
- Developed and modeled high-fashion/cosmetic ear protection and accessories.
- Orchestrated the migration of legacy data into a modern PLM system (Windchill), updating CAD models and drawings to align with new corporate/engineering standards.
- Drove concept, design, and delivery of technical assets for the next-generation variable earplug solution (Switch 2) from technical feasibility to final production.
- Created and documented new testing protocols and fixture design methodologies for cross-functional consistency.
- Drove the technical design, development, and implementation of metal 3D binder jetting for new product designs at production scale for the Swarovski collaboration.
- Led development, evolution, and training/mentorship for the organization-wide tolerance analysis framework used to elevate quality and manufacturability of all product lines.
Technologies: Product Lifecycle Management (PLM), Windchill PLM, CAD, Manufacturing, Design, Design Failure Mode and Effects Analysis (DFMEA), Design For Assembly (DFA), 3D Printing, 3D CAD, PTC Creo, Onshape, Fashion Design
Senior Mechanical Engineer
2016 - 2023
Intel
- Managed, modeled, and analyzed layouts for next-generation laptop and desktop systems.
- Led the generation of high-precision innovative thermal and mechanical solutions for mobile systems.
- Led and managed product segmentation work for forecasting and tech development initiatives.
- Managed and utilized prototype labs to support mission-critical projects.
- Developed and drove new project processes to drive greater discipline and consistency.
- Designed and conceptualized chassis, modules, components, and thermal solutions for use in large deployments of server racks and chassis used in supercomputer applications.
- Validated and maintained server systems for external customers such as Dell and Lenovo.
- Set up and managed server team, mechanical prototype, and test labs.
- Executed complex tolerance analysis and implemented GD&T for full rack systems, maintaining strict mechanical compliance for high-reliability data center environments.
- Generated models/prints of complex components and assemblies.
Technologies: Geometric Dimensioning & Tolerancing (GD&T), 3D CAD, 3D Printing, Manufacturing, Semiconductors, Deep Tech, Technology, Creative Tech, QA Documentation, Document Design, Reverse Engineering, Lab, Quality Management Systems (QMS), Product Lifecycle Management (PLM), Testing, Sheet Metal Design, Servers, Desktop, Mobile, 3D Design, Innovation, QA Process, Process Flows, Python
Design & Development Engineer – Food & Beverage Innovations
2016 - 2016
Jevo
- Managed design of subsystems for use in the Jevo automated jello shot maker, including a thermoelectric cooling block, recirculation tank, and a new moving/dynamic manifold dispensing system.
- Designed an updated manifold dispenser for more efficient filling and cleaning.
- Designed an updated thermoelectric cooling system for the rapid cooling of jello fluid.
Technologies: Design, 3D CAD, Manufacturing, Prototyping, Quality Management Systems (QMS), Product Lifecycle Management (PLM)
Innovation Engineer
2016 - 2016
Nike
- Developed next-generation technologies and designs for the Nike Global Football (soccer) team.
- Applied skills in materials research and development of various plastics, foams, metals, and elastomers.
- Drove the design and development of test fixtures for new internal standards.
- Developed impact comparison tests and methods for various sports equipment.
Technologies: Prototyping, Testing, Design, Document Design, 3D Design, Innovation, Innovative UX, Innovation Labs, Validation
Design & Development Engineer
2014 - 2015
Zebra Technologies Corporation
- Designed and developed next-generation tracking devices/systems for the NBA and the NFL.
- Developed low-pressure molding and prototyping methods and apparel integrations.
- Collaborated with electrical and antenna/RF engineers to ensure regulatory compliance.
- Tested, designed, evaluated, and assembled fixtures and low-pressure molding systems.
Technologies: Innovation, Wearables, Tracking, 3D Tracking, 3D CAD, 3D Design, 3D Printing, Testing, Validation, Manufacturing, Injection Molding, Mold Design, Antenna Design, Furniture, Fixtures, & Equipment (FF&E), Quality Management Systems (QMS), Product Lifecycle Management (PLM), Sewing
Mechanical Engineer (Contract)
2014 - 2014
Athos
- Designed and tested smart clothing and wearable devices.
- Prototyped and validated fabric circuit designs for use in next-generation sportswear.
- Developed test plans, procedures, and a test apparatus for validating smart clothing/hardware.
- Built charging dock prototypes for use with the Athos core module.
Technologies: Mechanics, 3D CAD, 3D Design, 3D Printing, Testing, Furniture, Fixtures, & Equipment (FF&E), Manufacturing
Mechanical Engineer – Misfit Wearables (Contract)
2014 - 2014
Misfit
- Developed technical documentation for wearable fitness trackers.
- Created technical engineering prints for components of the Shine and Flash fitness trackers.
- Supported the DFM of new designs and review of the project to ensure effective manufacturing.
Technologies: Design, 3D CAD, 3D Design, 3D Printing, NX CAD, Wearables, Tracking, Machining, Manufacturing
Senior Project Engineer
2012 - 2013
Case-Mate
- Designed, managed, and tested plastic, TPE, metal, and wood cell phone cases from concept to mass production.
- Researched, qualified, and managed global suppliers, ensuring high standards and timely delivery.
- Worked with and coordinated cross-functional teams across various geos.
- Implemented functional and cosmetic testing standards for validation and final design approval.
Technologies: Design, SOLIDWORKS, 3D CAD, 3D Design, 3D Printing, Fashion Design, Testing, Validation
R&D Engineer
2010 - 2012
Newell Rubbermaid
- Designed decorative hardware and window treatments from concept to mass production.
- Created highly cosmetic diecast parts, multi-material kitchen cabinet hardware, and automated test systems for cordless blind mechanisms.
- Developed test processes and fixturing for new hardware designs and implemented new standards for internal data management.
Technologies: 3D CAD, 3D Design, 3D Printing, SOLIDWORKS, Testing, Validation, Packaging, Research, Development, Product Lifecycle Management (PLM), Quality Management Systems (QMS), Furniture, Fixtures, & Equipment (FF&E), Data Management, Data Analytics
Associate Mechanical & Product Development Engineer
2007 - 2009
Motorola Mobility
- Designed, tested, and supported new and existing mobile communication devices from concept to mass production.
- Designed flexible circuits and interconnect systems, laid out main PCBs, and provided factory and test support.
- Developed vibrator alert and haptic feedback systems to meet user requirements.
- Identified and redesigned the keypad subsystem to prevent customer returns and field failures.
- Implemented a new adhesive solution to prevent component delamination for a cellular device.
Technologies: PTC Creo, 3D CAD, 3D Design, 3D Printing, PCB Design, Flex, Documentation, Testing, Quality Management Systems (QMS), Product Lifecycle Management (PLM), Six Sigma, Design for Six Sigma (DFSS), Design Failure Mode and Effects Analysis (DFMEA)
Project History
Loop Swarovski Collaboration
The Loop earplugs collaboration with the Swarovski crystal company. These were fashion-forward earplugs for trendy users and were notable as one of the first, if not the first, 3D metal-printed earplugs.
Next Generation Statistics NBA Tracker
A next-generation wearable tracker for the NBA, to be used with Zebra's NFC tracking systems, known as next-gen stats in the NFL. The project made it to production but was cut short due to a lack of interest from the NBA.
Case-mate Luxury Cases
Cases with luxury inlays and accents for the discerning consumer. This included real inlays of mother-of-pearl, stone, leather, and other luxury materials sourced from various suppliers and engineered for robustness and quality.
Intel Cryo-cool System
Designed and developed a sub-ambient thermal cooler for use with extreme thermal regimes used in gaming and high compute situations. The main issues revolved around 2 main issues: getting the system to work with different motherboard configurations and mitigating condensation risks around the CPU and cooling unit.
"Lise" Supercomputer (HLRN-IV)
A thermal design for a 48U liquid rack manifold for extremely demanding supercomputer loads at the Lise Supercomputer deployment. This project included design, development, testing, and deployment, as well as the layout and sourcing of a custom rack setup.
Motorola Cell Phones
The design and release of several Motorola phones in the early 2000s. This included the Q9h, Moto Cliq, an all-metal side-slide device, and support for several other unreleased designs. This was in the capacity of a subsystem owner.
Lifemech Ventilator
https://www.gofundme.com/f/efj4dc-lifemech-machines-saving-livesA large collaborative initiative during the pandemic to develop a low-cost ventilator option amid a shortage. It was successful in securing emergency medical approvals but fell short of its funding goal.
Education
2001 - 2006
Bachelor's Degree in Aerospace and Mechanical Engineering
University of Florida - Florida, USA
Skills
Libraries/APIs
Claude API
Tools
CAD, SOLIDWORKS, Nx, NX CAD, Visio, JMP, Claude Code
Paradigms
Testing, Six Sigma, Design for Six Sigma (DFSS), Thermal Management
Platforms
SharePoint, Adobe Suite, Desktop, Mobile
Languages
Python
Frameworks
Flex
Other
3D Printing, Prototyping, Tolerance Analysis, PTC Creo, Onshape, 3D CAD, 3D Design, Innovation, Projects, Teamwork, Design For Assembly (DFA), Product Lifecycle Management (PLM), Windchill PLM, Geometric Dimensioning & Tolerancing (GD&T), Injection Molding, FEA, FEM, Sheet Metal Design, Quality Management Systems (QMS), Failure Mode Effects Analysis (FMEA), Statistical Analysis, Design, Manufacturing, Deep Tech, Creative Tech, QA Documentation, Document Design, Reverse Engineering, Lab, Innovation Labs, Validation, Servers, QA Process, Process Flows, Wearables, Tracking, 3D Tracking, Mold Design, Furniture, Fixtures, & Equipment (FF&E), Machining, Verification, Fashion Design, Research, Development, Data Management, Data Analytics, Documentation, 3D Print Design, Collaboration, Luxury Goods, Vendor Selection, Vendor Management, Vendors & Suppliers, Root-cause Analysis (RCA), Remote Work, Design Failure Mode and Effects Analysis (DFMEA), ISO 9001, ANSYS, SAP, Minitab, Mechanics, Physics, Finite Element Method (FEM), Finite Element Analysis (FEA), Semiconductors, Technology, Innovative UX, Antenna Design, Claude Design, Sewing, Packaging, PCB Design, Thermal Testing, Thermal Analysis, Medical Devices
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