GARY PAUL HOPKINS
Aylestone,Leicester
Summary
Accomplished professional with extensive expertise in rubber tooling and engineering, specialising in compression, transfer, and injection mould tool design. Demonstrates proficiency in rubber product development, tool manufacture, assembly, and commissioning. Proven track record in new product introduction (NPI), project management, and manufacturing process development. Committed to continuous improvement and quality assurance through dimensional analysis and technical quotations. Skilled in customer liaison and adept at utilising CAD/CAM software including SolidWorks, PTC Pro/ENGINEER, Tangram Swift 2D CAD, Depocam/VISI CAM, and NC Graphics CAM. Experienced in CNC programming (ISO/G-Code), machine setup and operation, as well as conventional toolroom machinery such as grinding, manual milling, turning, tool fitting & assembly. Competent in MIG welding, arc welding, 3D printing & rapid prototyping. Proficient with Microsoft Office suite including Word and Excel.
Offering strong foundation in engineering principles and practical problem-solving skills. Knowledgeable about manufacturing processes, CAD software, and quality control techniques. Strong communication and teamwork abilities, coupled with keen attention to detail. Ready to use and develop precision tooling, fabrication, and project management skills in [Desired Position] role.
Adaptable and resourceful professional with strong problem-solving abilities, coupled with solid background in mechanical engineering and CAD design. Demonstrates excellent teamwork and communication skills, ensuring seamless project integration and collaboration. Committed to driving innovation and quality improvements in [Desired Position] role.
Overview
40
40
years of professional experience
Work history
Process & Tooling Engineer
The Harboro Rubber Co. Ltd.
2018.07 - 2026.07
- Returned to Harboro Rubber to provide technical leadership within the engineering department, becoming the company's lead 3D Design Engineer and taking responsibility for tooling development, manufacturing improvement and New Product Introduction.
- Lead 3D Design Engineer using SolidWorks.
- Developed precision rubber mould tooling and practical manufacturing solutions by producing and interpreting customer product models using SolidWorks.
- Took full responsibility for the company's 3D printing facility.
- Led complete NPI projects from initial customer enquiry through tooling design, manufacture, production trials, and final customer approval.
- Created work instructions, dimensional analysis, and project documentation for customer submission, ensuring compliance with IATF 16949 quality standards.
- Introduced and established post-machining operations after customer processes were brought in-house.
- Developed machining processes and maintained quality standards using Bridgeport milling machines and Jones & Shipman grinding equipment.
- Worked closely with customers, production, manufacturing and quality departments to ensure products were successfully introduced into production.
- Supported continuous manufacturing improvement across the business.
- Key Responsibilities & Achievements
Toolroom Manager / Tooling Engineer
Advanced Mould Tooling Ltd.
2012.01 - 2018.07
- Returned to Advanced Mould Tooling after being invited back by the owner to provide experienced technical leadership during a critical period for the business.
- Managed tooling projects from concept through manufacture and delivery.
- Designed compression, transfer and injection rubber mould tooling using PTC Pro/ENGINEER.
- Created complete 3D models and detailed manufacturing drawings, facilitating accurate tool production.
- Programmed CNC machining centres using Depocam (VISI CAM).
- Oversaw daily operations of specialist rubber mould toolmaking company, ensuring efficient workflow and quality standards.
- Prepared quotations and provided technical advice directly to customers.
- Assisted in production planning, quality assurance, and continuous improvement initiatives to enhance operational effectiveness.
- Key Responsibilities & Achievements
Tooling & Product Engineer
The Harboro Rubber Co. Ltd.
2008.01 - 2012.01
- Developed tooling and manufacturing solutions for new products.
- Specified and sourced tooling, equipment, and manufacturing processes to enhance production capabilities.
- Managed tooling development and New Product Introduction within Technical Department to align with product specifications and customer requirements.
- Managed projects from customer enquiry through production and customer approval.
- Managed production trials and customer approvals.
- Worked closely with suppliers, production and quality departments.
- Implemented targeted manufacturing improvements to optimise production workflows.
- Key Responsibilities & Achievements
Senior Tool Designer / CAD/CAM Engineer
Advanced Mould Tooling Ltd. *(formerly T.A. Knight Ltd.)*
2004.01 - 2008.01
- Designed compression, transfer and injection rubber mould tooling using PTC Pro/ENGINEER.
- Produced complete CAD models and manufacturing drawings.
- Programmed CNC machining centres using VISI CAM.
- Facilitated transition to new company following T.A. Knight acquisition, ensuring continuity in engineering operations.
- Defined key responsibilities and achievements for engineering projects, enhancing clarity and direction for team efforts.
- Assisted engineering leadership in managing daily operations and coordinating project tasks, contributing to overall project success.
- Prepared quotations for new tooling projects.
- Worked directly with customers throughout tooling development.
- Supported manufacture, assembly and commissioning of tooling.
Tool Designer → CAD/CAM Engineer → Operations Manager
T.A. Knight Ltd.
1991.01 - 2004.01
- Designed compression, transfer and injection rubber mould tooling.
- Progressed from traditional drawing board design to leading the company's transition into CAD.
- Introduced and managed the Tangram Swift 2D CAD system.
- Set up, programmed and personally operated the company's Fadal CNC Vertical Machining Centre using ISO programming and NC Graphics CAM software.
- Manufactured tooling directly from CAD/CAM data, supporting machining, fitting, assembly and welding.
- Facilitated introduction of enhanced CNC machining capabilities and advanced CAD/CAM technologies.
- Advanced through senior engineering and operational roles, modernising business with CAD/CAM and CNC manufacturing technologies.
- Outlined primary duties and contributions in roles held.
- Progressed to Operations Manager with responsibility for day-to-day manufacturing operations.
- Introduced shift working to increase manufacturing capacity.
- Delivered training for employees in CAD, CAM, CNC machining, and workshop practices, improving skill levels and operational knowledge.
- Prepared quotations and worked directly with customers to develop practical engineering solutions.
Engineering Apprentice
Wadkin plc, Leicester
Leicester
1987.01 - 1991.01
- Recognised for outstanding achievements during engineering apprenticeship, contributing to project success and team objectives.
- Overall Craft Apprentice of the Year.
- Completed a traditional four-year engineering apprenticeship with one of Leicester's leading engineering manufacturers.
- Acquired hands-on experience through comprehensive training and skill development.
- Gained practical experience in broaching, gear cutting, milling, turning, grinding, planing, assembly and CNC machining.
- Higher National Certificate (HNC) in Engineering.
- Ordinary National Certificate (ONC) in Engineering.
- Initial apprenticeship completed through the Leicester Engineering Training Group (LETG).
- Chosen for role in Production Office based on demonstrated technical skills and problem-solving abilities.
- Supported offline CNC programming together with jig and tool design.
- Assisted in implementing Wadkin's first AutoCAD and CAM systems, laying groundwork for CAD/CAM expertise that shaped my engineering career.
Education
Higher National Certificate (HNC) - Engineering
Ordinary National Certificate (ONC) - Engineering
Four-Year Engineering Apprenticeship - undefined
Wadkin plc
undefined
Leicester Engineering Training Group (LETG)
Skills
- Rubber Tooling & Engineering
- Compression Mould Tool Design
- Transfer Mould Tool Design
- Injection Mould Tool Design
- Rubber Product Development
- Tool Manufacture
- Manufacturing & Toolroom
- CNC Programming (ISO / G-Code)
- CNC setup
- Conventional Toolroom Machinery
- 3D printing
- CAD / CAM Software
- SolidWorks
- PTC Pro/ENGINEER
- Tangram Swift 2D CAD
- Depocam / VISI CAM
- NC Graphics CAM
- Process development
- Continuous Improvement
- Quality Assurance
- Dimensional Analysis
- Technical Quotations
- Project Management
- Customer Liaison
- Product introduction
- Manufacturing & Toolroom
- Microsoft Excel
- Microsoft Word
- Microsoft Excel
INTERESTS
Outside of work I enjoy applying my engineering skills to practical projects, including campervan restoration and bespoke conversions, vehicle maintenance, mechanical repairs, welding, fabrication, electrical work, plumbing, woodworking and home improvement., I enjoy learning new engineering skills through technical manuals, manufacturer documentation and online resources, and I take pride in solving practical engineering challenges for family, friends and my own projects., References available on request.
CAREER HIGHLIGHTS
- Managed complete New Product Introduction (NPI) programmes from customer enquiry through tooling design, manufacture, production trials and final customer approval.
- Project managed customer programmes while ensuring delivery to specification, quality requirements and agreed timescales.
- Produced and maintained project documentation, work instructions, dimensional analysis and final quality submission paperwork within an IATF 16949 certified manufacturing environment.
- Time-served Toolmaker with extensive experience operating conventional toolroom machinery, including CNC machining, manual machining, tool fitting, MIG welding and arc welding.
- Designed compression, transfer and injection rubber mould tooling using PTC Pro/ENGINEER.
- Introduced and implemented CAD/CAM, CNC machining, 3D printing and post-machining manufacturing processes.
- Extensive experience programming, setting up and operating CNC machining centres.
- Strong customer-facing engineering experience, providing quotations, technical advice and practical engineering solutions.
- Experienced in manufacturing process improvement, staff training and continuous improvement.
ADDITIONAL INFORMATION
- Full UK Driving Licence (Car)
- Full UK Motorcycle Licence
Affiliations
- Outside of work I enjoy applying my engineering skills to practical projects, including campervan restoration and bespoke conversions, vehicle maintenance, mechanical repairs, welding, fabrication, electrical work, plumbing, woodworking and home improvement. I enjoy learning new engineering skills through technical manuals, manufacturer documentation and online resources, and I take pride in solving practical engineering challenges for family, friends and my own projects.
Timeline
Process & Tooling Engineer
The Harboro Rubber Co. Ltd.
2018.07 - 2026.07
Toolroom Manager / Tooling Engineer
Advanced Mould Tooling Ltd.
2012.01 - 2018.07
Tooling & Product Engineer
The Harboro Rubber Co. Ltd.
2008.01 - 2012.01
Senior Tool Designer / CAD/CAM Engineer
Advanced Mould Tooling Ltd. *(formerly T.A. Knight Ltd.)*
2004.01 - 2008.01
Tool Designer → CAD/CAM Engineer → Operations Manager
T.A. Knight Ltd.
1991.01 - 2004.01
Engineering Apprentice
Wadkin plc, Leicester
1987.01 - 1991.01
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Leicester Engineering Training Group (LETG)
Four-Year Engineering Apprenticeship - undefined
Wadkin plc