Product Development / Mechanical R&D Engineer

I turn rough ideas into machines that work.

7+ years turning requirements into working hardware. 50+ client-funded systems engineered and delivered from requirements through build, test, and handover.

50+ client-funded prototypes ≈300 units in one product line 250,000 test cycles on one research machine
Moustafa Sharaf, Product Development and Mechanical R&D Engineer 50+ builds
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Selected delivery context
Pulsar / Si-WareEBankUniversity systems · OmanProducts exported · Gulf & Europe

Proof before promises

Engineering output you can count.

No company-wide claims. Only systems I directly led or engineered with the MARS-Z team, and the results they produced.

50+

Client-funded machines and prototypes I directly engineered or led through delivery with the MARS-Z team

≈300

Units manufactured after I led the move from prototype into repeatable production

250,000

Test cycles run by a research rig I engineered for a published dental study

90%

Cheaper than commercial insulin pumps — my M.Sc. device, published by IEEE

Custom inertial rate table test equipment
Client-side analysis32.8 ppmFS nonlinearity

Featured case study

High-precision Inertial Rate Table

A table that turns at a rate you can trust, so a gyroscope can be judged against it.

01 / Challenge

Deliver steady, programmable rotation across a wide speed range, while keeping the machine easy to service and practical to build.

02 / Engineering work

Led the mechanism, drivetrain, sensing, control integration, fabrication coordination, and iterative validation. Combined mechanical refinement with encoder feedback and repeatable test routines.

03 / Evidence

Client-side analysis measured 32.8 ppmFS encoder-to-command nonlinearity over a ±300 dps sweep. The final client-run session also demonstrated sinusoidal motion up to 15 Hz at 400 dps peak.

Most relevant work first

Built, tested, delivered.

The closest match to this role comes first. Open any card for the full story.

More engineering range

Six more systems, built the same way.

12 projects in total

Takes 30 seconds

Can you save the prototype?

Three real trade-offs from actual projects. Your answers show how you think.

Engineering challenge

Save the prototype.

ReliabilitySpeedCost
Scenario 1 of 3

PROTOTYPE STATUS AT RISK

The brief is vague, but the deadline is moving. What do you do first?

Reliability0
Speed0
Cost control0

Design to hardware

Same machine, both ends of the job.

Drag the handle. Left is the CAD model, right is the machine running on the bench with its own control unit and live plot.

The inertial rate table built and running on the bench CAD model of the inertial rate table CAD Built
Moustafa Sharaf practicing competitive archery Precision outside the lab

The engineer behind the work

I work where everything has to meet.

I am a Mechanical Engineering M.Sc. and Lead R&D / Product Development Engineer at MARS-Z. My best work sits where mechanics, electronics, control, the workshop, suppliers, and users all have to become one working product.

I lead a permanent team of 3 engineers and 4 full-time technicians. I use AI to move faster on software and documentation. My firmware and prototype-PCB work is integration level, not specialist level, and I say that upfront.

I also shoot competitive archery — the same discipline of precision, repeatability, and calm focus carries into my engineering work.

M.Sc. Mechanical EngineeringAlexandria University3 research contributions1st place · MATE ROV EgyptCompetitive archery

Verified credentials

Checked, stamped, and published.

Postgraduate M.Sc. Mechanical Engineering Alexandria University, awarded February 2026. Thesis: a developed design for a low-cost auto-controlled insulin pump.
Undergraduate B.Sc. Mechanical Engineering Alexandria University, June 2019. Graduation project: Power-to-Gas sustainable energy system — Best Graduation Project, Energy Track, Egyptian Engineering Day.
Conference IEEE ITC-Egypt 2025 Presented “A Developed Design of Low-Cost Insulin Pump for Automated Insulin Delivery (AID) System”.
Peer-reviewed Three published contributions IEEE ITC-Egypt 2025 · The Journal of Prosthetic Dentistry 2024 · Scientific Reports 2024. Devices I engineered were used to produce the published results.

Have a hardware problem that keeps failing?

Let’s turn it into something that works.

More than seven years of hands-on engineering: I design custom machines and electromechanical products, build them, test them, and hand them over working. Open to Product Development, Mechanical R&D, Robotics, Simulation and Research Engineering roles.

Or call directly — +20 111 772 6062

Challenge

My contribution

Evidence / outcome