Mike van Wyk

MECHANICAL ENGINEER

Skills Overview

Mike is a versatile mechanical engineer with a strong foundation in mechatronics, product development, and rapid prototyping. He has worked across industries including medical devices, industrial automation, and sustainable materials, applying his expertise in CAD design, embedded systems, and process optimisation to develop innovative, manufacturable solutions. With a hands-on, problem-solving approach, he excels at integrating mechanical and electronic systems, bridging the gap between concept and reality.

MECHANICAL DESIGN & PRODUCT DEVELOPMENT – Mike brings extensive experience in mechanical design, taking concepts from early-stage development through to manufacturable solutions. His background spans medical devices, IoT hardware, and industrial automation. In the Axon 2 EEG headset project, he 3D-printed prototypes, designed jigs and fixtures for testing, and integrated mechanical components with electronics. He also developed packaging for Axon’s first large-scale medical trial (100+ participants). Mike works closely with electrical, software, and manufacturing teams to ensure reliable, manufacturable designs with a strong user focus.
MECHATRONICS & EMBEDDED SYSTEMS INTEGRATION – Mike has a strong mechatronics foundation and specialises in integrating mechanical systems, electronics, and control systems. At Nilo Ltd, he helped develop a high-pressure, PLC-controlled syringe pump for chemical injection in a twin screw extruder, handling flow rates over 50 bar. His responsibilities included mechanical/electrical design, stress analysis, control programming, and commissioning. He also created 3D-printed micro-feeders to improve powdered chemical feeding. Experienced with embedded systems and sensor-driven automation, he has worked with force sensors, actuators, and machine learning. He codes in Python and C++ and collaborates with multidisciplinary teams to integrate complex mechatronic systems.
PROCESS OPTIMISATION – Mike has strong experience in process optimisation for industrial and R&D settings. At Nilo Ltd, he upgraded the R&D facility, improved factory layouts, and designed a compact plant room for efficient integration. He has also conducted energy audits and performance analyses on large chiller plants, identifying inefficiencies and implementing cost- and energy-saving solutions. His data-driven approach delivers practical engineering outcomes that improve reliability, sustainability, and performance in close collaboration with operations and maintenance teams.
TECHNICAL DOCUMENTATION – Mike is proficient in producing technical documentation and drawings. He has created detailed reports, PFDs, technical drawings, and assembly instructions across medical, automation, and R&D sectors. His documentation supports manufacturing, testing, and system integration, ensuring information is clear and accessible for engineers, technicians, and stakeholders. His work contributes to design validation, compliance, and long-term maintenance.

SolidWorks Professional Mechanical Design

Caliber has experience in the Agriculture industry

Caliber has experience in the Aerospace industry

Caliber Design has experience in the Biofuel industry

PERSONAL STATEMENT

I’m a mechanical engineer with a passion for solving complex problems and bringing ideas to life. My experience spans industries including medical devices, IoT, industrial automation, and sustainable materials, where I’ve worked on everything from precision product development to large-scale process optimization. With expertise in mechanical design, mechatronics, rapid prototyping, and embedded systems, I thrive in the space where hardware and software meet.

I hold a Master of Engineering (First Class Honours) from Auckland University of Technology and have a background in electro-mechanical engineering. I enjoy working on challenging projects that require a mix of creativity, technical precision, and hands-on problem-solving.

Outside of work, I’m passionate about health and fitness, mountain biking, and the outdoors. I’m also a hobbyist 3D printing enthusiast, always experimenting with new designs. A lifelong music lover, I play the drums and enjoy jamming whenever I get the chance.

Project Experience

EV Charger Development

Supporting the development and testing of a new range of outdoor EV chargers, with a focus on conducting and documenting compliance tests (IP and mechanical) to meet US and European regulatory requirements. Working alongside production and systems engineering teams to resolve prototype challenges and progress the product to a manufacturable version. Delivering technical documentation and detailed sheet metal drawings to streamline the transition from design through to production.

ZERO-CAST

Smart Brace Prototype

Smart Brace is a sensor-integrated wrist brace for rehabilitation. I developed a smart wrist brace prototype integrating force sensors and machine learning algorithms to enhance rehabilitation tracking for wrist injury patients. I was responsible for mechanical design, embedded systems integration, and prototype development, ensuring seamless interaction between hardware and software.

EXSURGO

Axon EEG Headset Development

Contributed to the mechanical design and prototyping of the Axon 2 EEG headset, ensuring seamless integration of mechanical and electronic components. Developed 3D-printed prototypes, jigs, and testing fixtures to optimize assembly processes and performance validation. Designed a packaging solution for Axon’s first large-scale clinical trial with over 100 participants.

DUBAI INTERNATIONAL AIRPORT

Energy Audit

Conducted a comprehensive energy audit of Dubai International Airport’s chiller plants and HVAC systems, analysing energy consumption patterns, system inefficiencies, and performance optimisation strategies. Identified energy-saving opportunities and provided technical recommendations that contributed to reducing operational costs and improving overall efficiency.

NILO

High-Pressure Syringe Pump

Designed and developed a high-pressure, PLC-controlled syringe pump for injecting liquid chemicals into a twin screw extruder (TSE) at controlled flow rates exceeding 50 bar. Responsible for mechanical and electrical design, component selection, stress analysis, PLC programming, and commissioning to ensure reliable high-pressure operation.

3D-Printed Micro-Feeders

Designed and manufactured custom 3D-printed micro-feeders as a low-cost, adaptable solution for feeding powdered chemicals into a TSE system. Improved material flow consistency and reduced manual handling, supporting R&D efforts in sustainable material development.

UPWORK CLIENT

Sensor-Integrated Hinge

Developed a proof-of-concept sensor-integrated hinge incorporating a load cell and LCD interface to measure applied forces in real-time. Designed and built the mechanical assembly, sensor interface, and embedded electronics, ensuring accurate force measurement and usability.