Helder Teixeira Da Costa

Design Manager 2025-Present Stormking/GRP Aspects

• Review technical specifications and architectural drawings provided by customer, generate 3D models and 2D technical drawings using Inventor. Once the customer approves, I generate the Bill of material (BOM) into MRP (dynamics 365 business central). I also design and assess the load capacity of all GRP products, accounting for the weight of a falling adult (1kN).
• Solely responsible for new tool designs of bespoke products. I initially review the customer specification and architectural drawings, create an inverse 3D model in Inventor of the finished component, generate 2D models showings critical dimension, drafts and tolerances. I am responsible for material and process selection; tools can be made from silicon or GRP.
• Manage the workload of the technical team ensuring the weekly output target as defined by management is met.
• Provide daily support for manufacturing engineers, by finding root cause of any issues and resolving them.
• Review new client briefs and ensure all new products achieve improved energy ratings of 0.16 U-value, in addition to being fire rated to BS EN 13501-5

Technical Team Leader 2023-2025 IG Elements

• Implemented design methodologies such as Design for Assembly (DFA), Design for Manufacture (DFMA), and Design for Testing (DFT), concentrating on performance, manufacturability, serviceability, and testing.
• Managed a team of two Technical Design Engineers and five Production Operatives ensuring product delivery in terms or quality time and cost (QTC).
• I adopted quality processes such as fish bone analysis, which highlighted flaws in the chop spray manufacturing method. I trialled resin transfer moulding, which produced an additional 18-20 parts daily, surpassing original KPi’s by nearly 50%.
• I designed and managed the installation and testing (in house water and loading test) of a GRP dormer with a roof section of a residential building accounting all interfaces and coordinating subcontractors required for this task. The water test initially failed, but the issue was resolved before the official test, resulting in a cost saving of over £50,000 that would have been incurred had the failure occurred during the official testing.

Technical Design Engineer 2020-2023 IG Elements

• I designed standardised products for Taylor Wimpey, Barratt, Keepmoat and Vistry Homes, totalling over 60 product variants. I assessed architectural drawings technical specification associated with each product, and generated 3D models and 2D technical drawings using SolidWorks.
• I generated SOP’s for training and operation designed to teach production engineers how to manufacture GRP components resulting in increased efficiency and product quality.