Danny Webb

MECHANICAL ENGINEER

Skills Overview

Danny has built his experience in industrial machinery design, aerospace and R&D. He has primarily worked in development adn manufacturing and is capable of turning to any problem with an open approach. With a strong technical background and proactive attitude, he has become an efficient engineer across a variety of industries. Danny has a masters degree in mechanical engineering and an enthusiasm to learn.

PRODUCTION EQUIPMENT & MACHINE DESIGN – Danny has designed equipment for materials handling, packaging, heavy production lines and high pressure product testing. His designs have involved pneumatics, hydraulics, vacuum, conveyors, chain drives, guides and more. Danny has designed new equipment by drawing on technologies from other industries and can think around problems with an open mind. His portfolio of projects includes various equipment for a continuous heavy production line, ventilation systems, support structures and packaging equipment.
DESIGN FOR MANUFACTURE & ASSEMBLY – Experienced with a range of manufacturing methods including machined from solid, sheet metal, fabrications and moulding in metals, polymers and composites. He has designed and built several complex assemblies and has developed the tools to assess every design against DFMA methodology. He has regularly worked closely with suppliers to realise robust designs that minimise risks and defects and deliver quality parts.
MANUFACTURING ENGINEERING – Installed and set up a range of manufacturing equipment and processes within aerospace, medical devices and composite manufacture. Danny has created operating procedures and maintenance and training documents within strict QMS that ensure proper traceability and document control. Danny has supported audits within the medical device industry, drawing on his extensive experience developing validation protocols and procedures for inspection and manufacturing equipment.
DYNAMIC PROBLEM SOLVING – Never one to shy away from a difficult problem, Danny has worked extensively in R&D where creative thinking and innovation are a must. He has worked across a diverse range of engineering environments — from fast-paced start-ups to established manufacturing and quality-focused organisations — Danny has developed the ability to adapt his problem-solving approach to suit the demands of any role or industry. This experience has sharpened his ability to make confident, well-reasoned decisions under pressure, keeping projects on track even as requirements evolve. Clients can expect an engineer who not only solves the problem at hand, but anticipates downstream implications across design, manufacture, and quality to deliver robust, lasting solutions.
FIXTURES & TOOLING – Danny has worked on fixtures and tooling for several innovative products. He is always keen to collaborate with technicians and manufacturing teams and to engage with the end user; designing tools that work for the user is paramount for maintaining quality. Example projects include hand tools for composite processing, aerospace rotor assembly tooling and assembly fixtures for large water tanks.

SolidWorks Professional Mechanical Design

Caliber has experience in the Aerospace industry

Caliber Design has experience in the Biofuel industry

Caliber has experience in the Agriculture industry

PERSONAL STATEMENT

My passion for engineering stems from an innate interest in how things work, I was forever taking apart household items as a child keen to understand the mechanisms inside. I have enjoyed working in R&D and start-ups where I have tackled a variety of engineering problems and technologies that I regularly draw on when solving problems. I have worked on projects from large support structures for manufacturing down to critical aviation components and tooling. I use a practical, holistic approach to overcome barriers and complete projects without delay for clients. Outside of work I spend my free time enjoying the outdoors, playing sports and pursuing a variety of practical hobbies.

Project Experience

OSSIS / The Machinists

Medical Devices – Manufacturing Engineer

Danny supported the manufacturing team to set up new equipment and processes to enable the expansion of the Ossis product line for two new product families. This work focussed on building up the quality management system and manufacturing systems to meet the strict quality requirements set out in ISO 13485. Danny set up manufacturing equipment and processes, then ran comprehensive equipment and process validations to prove production capability and consistency. He worked directly with the supplier to improve quality and traceability for machined implants and plastics tools. Danny developed and implemented a new 3D scanning system for the analysis of complex organic implants. The system was successfully integrated into the production workflow, delivering high-quality data that directly informed DFM and played a critical role in establishing new product manufacturing processes. Standardised templates were also developed to ensure consistency, repeatability, and reliability across all inspection outputs, providing the client with a robust foundation for ongoing quality control.

Heavy Roll Packaging Machine

Managed the research and decision making over a packaging solution for a large composite rolled product. The final solution involved refurbishing and repurposing an existing baling machine to neatly package the product. Activities included organising demonstrations and testing, carrying out refurbishment of hydraulic parts and conveyors, designing and installing pneumatic modifications and working with automation specialist to reprogramme the machine before final installation. The final solution was cost effective and implemented faster than designing from the ground up.

Material Accumulator

Designed and built a large (6x3x2m) material accumulator for a heavy composite manufacturing line. Design activities included calculations for frame structure, bolted connections and drive train; sourcing pneumatics, gearboxes and drive train and issuing drawings for sheet metal and fabrications. Tracked all parts through procurement before building and installing the equipment myself.

Platform, Stairway & Support Design

Supporting the structures team to design supports for a range of equipment including conveyors, washers and handling equipment. I designed large access platforms and stairways to ASNZ 1657 and EN 14122 as well as ancillary pipe work. Inventor was used to design predominantly stainless steel structures either folded and bolted or welded.

OIL & GAS INDUSTRY

High Pressure Test Rig

Designed a high pressure and temperature test chamber for developing a new product for the oil and gas industry. Developed a bespoke test rig operating up to 180C and 700bar with external control room. Calculated theoretical loads inside the test rig to inform the seal selection for the critical end seal. Issued drawings for machined parts and tracked parts through procurement and assembly. Designed and assembled hydraulic circuit, hydraulic control panel, ceramic heating system and insulation box around the test rig. Worked within a small multidisciplinary team to test and develop the product whilst tweaking the test rig as necessary and managing the data collection.

Rotor Components for an Electric Motor

Designed rotor components for a new electric motor for aerospace applications operating up to 10,000 rpm. Communicated with suppliers to circumvent DFMA issues, generated parametric models and issued technical drawings for multi-op machined parts. Embedded components in large motor assembly model and issued assembly drawings for manufacturing teams. Key contributor to first rotor build for the company and organised first batch of destructive testing with successful results.

Motor Assembly Fixture

Managed subcontracted work for a final assembly jig for a new electric motor. Communicated design intent and criteria with the contractor to capture new design improvements and meet tight tolerances. Designed auxiliary tooling and jigs to deliver a full working product with documented instructions to help develop the SOP. Clear communication with contractors and technicians was essential due to high loads creating a complex operating procedure. Developed good working relationship with suppliers to turn around urgent parts on time.

GOOD BUGGER AWARD

January 2025

Danny Webb got the Christchurch award to acknowledge his impressive achievement of two NPS of 10 from two clients. The first was a medical client we’ve been wanting to work with for years and he was the first Caliber engineer to work there. Being medical, they have very high standards, and Danny blew them away and really cemented that relationship for future work together. The clients appreciated Danny’s attention to detail and the way he could tackle a bunch of tasks effectively, and the way he looked ahead at the start of the project and anticipated what could go wrong.