Shuaib B.

Mechanical Engineer | CFD · FEA · CAD | 2× USPTO Patents | Top Rated Plus

Overview:
Mechanical engineer specialising in CFD, FEA, and thermal systems, with two granted USPTO patents in cooling technology (US 12,452,991 · US 12,453,048). I design and validate heat exchangers, HVAC systems, centrifugal fans, and refrigerant loops in OpenFOAM, ANSYS Fluent, SimScale, and SolidWorks Flow Simulation. Top Rated Plus on Upwork , 85+ contracts, 3,000+ hours, $275K+ earned. Based in Cape Town, South Africa. Former CTO of a product development company.

I don't ship black-box "trust me" reports. Every deliverable carries the mesh, Y+ verification, residual history, and flow-uniformity evidence behind the numbers. Results your team can defend in a design review. And because I've built a Python+OpenFOAM automation pipeline, I run parametric sweeps hand-meshing freelancers can't: on Heat exchanger contracts(2026), a 224,000-point overnight sweep on a centrifugal heat exchanger surfaced a geometry that more than doubled system COP.

Core Services

CFD: heat exchangers, HVAC, centrifugal fans, ducts, refrigerant loops; conjugate heat transfer, natural convection, multiphase flow with species transport, turbulence modelling (k-ω SST, realizable k-ε, LES where warranted).
FEA / Structural: stress, fatigue life, vibration, drop/impact testing, nonlinear and topology optimisation, composites (CalculiX, ANSYS Mechanical).
Acoustic / NVH: noise prediction and NVH analysis.
CAD & Documentation: SOLIDWORKS parametric modelling, assemblies, sheet metal, weldments, surface modelling, photorealistic rendering, and manufacturing-ready technical drawings.

Software: OpenFOAM, ANSYS Fluent, ANSYS Mechanical, SimScale, STAR-CCM+, COMSOL Multiphysics, SolidWorks (CAD + Flow Simulation), CalculiX, Gmsh, AutoCAD, Fusion 360, MATLAB, Python.

Selected Work:
Heat exchanger (2026) — 224k-point automated CFD sweep on a centrifugal heat exchanger; found a geometry that >2× system COP.
Brine–CO₂ corrosion modelling, oil-field pipework (2025–26, active) — multiphase CFD with species transport.
USC approved Valve (2025) — backflow-preventer pressure-loss validation to AWWA C510 across six configurations.
EvansWerks (2023–26) — 32-month principal-engineer engagement for Product development
Patented airless tyre (2026) — coupled FEA + thermal feasibility on an adaptive airless tyre (CalculiX + Gmsh).
toronto university wind tunnel (2025) — contraction-section CFD achieving <1% velocity-profile RMS in the working section. Credentials: Mechanical Engineering, advanced simulation focus (in progress) · BSc.Eng (Hons) Mechanical Engineering, UKZN · Aerospace Systems Research Group affiliate since 2019 · 2× granted USPTO patents in cooling-system technology. Industries: Aerospace, Automotive, Energy, Manufacturing, Medical Devices, Consumer Products, HVAC, Electronics Cooling.