Design and manufacturing
SolidWorks, CATIA V5, Fusion 360, GD&T, tolerance analysis, CNC machining and design for manufacturability.
Mechanical + Aerospace Engineering Portfolio
Engineering work built for real constraints.
I'm Khaled Megahed, an MEng graduate in Engineering Science and a BEng graduate in Aerospace Engineering. This portfolio brings my mechanical design, analysis, manufacturing and aircraft systems work together in one place.
40 kgLink 5 structural load test passed
13.89 hpPreliminary aileron EHA motor sizing
536 nmiSnoopy aircraft concept range
Technical capabilities
One engineering foundation across mechanical and aerospace work.
Analysis and simulation
ANSYS FEA/CFD, stress analysis, topology optimization, MATLAB, Python, Simulink and engineering trade studies.
Mechanical systems
Hydraulic actuation, component sizing, requirements, verification, FMEA, QA/QC and technical documentation.
Aircraft engineering
Aircraft sizing, performance, aerodynamics, mission analysis, propulsion integration, airworthiness and certification planning.
Engineering project evidence
Decisions, calculations and honest results.
Each project shows the problem, my individual contribution and the outcome, including limitations and lessons learned.
Case study / 01Individual mechanical design project
Fowler Flap Link 5: CAD, FEA, CAM and Test
Developed a manufacturable aluminum linkage for a Fowler flap mechanism, moving from assembly geometry through analysis, machining and physical test.
My contribution
I modelled the assembly and Link 5 in Fusion 360, resolved the three-point linkage geometry, used topology and static stress analysis to remove low-stress material, added reinforcement at load paths, selected tolerances and created CNC milling toolpaths.
Result and engineering judgment
The manufactured part passed a 40 kg static structural test with a calculated safety factor of 2.01. Kinematic testing exposed interference with Link 6 during retraction. I documented the cause and proposed geometry and contact-checking changes instead of hiding the partial failure.
40 kgstatic load passed
2.01calculated safety factor
1.61 gactual vs predicted mass variance
Fusion 360FEACNC CAMGD&TDFMTolerance analysis
Case study / 02Individual aerospace systems design report
BumbleB Control-Surface Actuation System
Selected and sized actuation architectures for the ailerons, elevator and rudder of a conceptual aircraft as control loads evolved.
My contribution
I compared linear and rotary, hydraulic, electro-hydraulic and electromechanical options, then built an Excel sizing model for actuator speed, piston area, flow, motor power, accumulator volume and pipe diameter. When updated loads invalidated the original EMA choice, I revised the architecture to EHA and recorded assumptions and limitations.
Result and engineering judgment
The preliminary aileron case produced a 13.89 hp motor requirement, 5.79 GPM flow, a 61.54 in³ accumulator and a 0.004 m pipe diameter. The report also identified unrealistic leakage outputs for correction in future model revisions.
13.89 hpaileron motor estimate
5.79 GPMpreliminary flow
3control-surface systems
HydraulicsExcel modellingTrade studiesRequirementsTechnical reporting
Case study / 03Three-person conceptual aircraft design
Snoopy-Series Light Sport Aircraft
Developed a two-seat light aircraft concept for training and sightseeing, sized to a formal request for proposal and airworthiness constraints.
My contribution
I owned weight analysis, aircraft performance, mission design and aerodynamics. My work included a sensitivity analysis, range and endurance calculations, performance checks and aerodynamic evaluation supporting the final configuration.
Result and engineering judgment
The concept achieved a 1234 lb takeoff weight, 120 kt cruise speed and 536 nmi range. The selected design point used T/W of 0.2987 and W/S of 13.5 lb/ft² while meeting the stated RFP requirements.
536 nmiconcept range
120 ktcruise speed
1234 lbtakeoff weight
Aircraft sizingPerformanceAerodynamicsMission analysisXFLR5
Case study / 04Four-person aerospace systems project
A320 Hybrid-Electric Propulsion Retrofit
Evaluated three concepts for reducing fuel use and CO₂ emissions on an Ottawa-to-Winnipeg reference mission.
My contribution
My assigned work covered the feasibility study, weight estimation, performance and systems implementation. I also collaborated on requirements, certification research and FMEA, and helped evaluate concepts against emissions, cabin capacity, weight, safety, turbine efficiency, configurability and simplicity.
Result and engineering judgment
The weighted trade study selected the parallel hybrid configuration. It met the landing-weight restriction with 229 kg of margin. The study also showed the tradeoff clearly: 56 fewer passengers were required to achieve an estimated 0.013 MT mission CO₂ saving.
229 kglanding-weight margin
0.013 MTestimated CO₂ saving
3concepts evaluated
Systems engineeringWeight estimationTrade studyFMEAAirworthiness
Case study / 05Individual airworthiness planning project
A320 Hydrogen Fuel-System Certification Plan
Prepared a draft certification plan for integrating a cryogenic liquid-hydrogen fuel system into an A320-class aircraft.
My contribution
I defined the modification, documentation, schedule, compliance methods and coordination plan. The compliance matrix mapped structural, thermal, fuel-system and emergency requirements to analysis, design review, simulation, testing and FMEA evidence.
Result and engineering judgment
The plan identified the required fuselage reinforcement, insulation, compatible piping, continued-airworthiness updates, ground vibration testing and safety assessment needed to support the proposed configuration.
30 pagescertification plan
5evidence methods
1traceable compliance matrix
Certification planningCARs/AWM 525Compliance matrixFMEATechnical documentation
About
Technical depth with operational discipline.
My background spans CAD, FEA, hydraulic systems, CNC machining, GD&T, design for manufacturability, aircraft performance, trade studies, FMEA and technical documentation. I enjoy turning broad requirements into a traceable engineering decision.
At Strategic Aviation, I worked around aircraft and heavy ground equipment in a fast-paced environment where safety, clear communication and coordinated execution were essential.
2026
Master of Engineering, Engineering ScienceLaurentian University · Mechanical engineering focus
2024
Bachelor of Engineering, Aerospace EngineeringCarleton University
Contact
Let's talk about the work.
I am currently based in Sudbury, Ontario, and open to relocation anywhere.