Lewis Bower

MECHANICAL ENGINEER

Skills Overview

Lewis is an experienced mechanical engineer with a strong foundation in aerospace engineering. During his time at the Advanced Manufacturing Research Centre, he developed expertise in designing, validating, and manufacturing complex systems across sectors including aerospace, automotive, energy, and defence. He has a keen eye for manufacturability and is passionate about developing design concepts from early stage through to full production. Lewis brings a proven ability to lead technical projects end-to-end, working effectively within multidisciplinary teams to deliver practical, high-quality, and sustainable engineering solutions.

DESIGN FOR MANUFACTURE – Lewis has significant experience in design for manufacture, supported by a strong understanding of a wide range of advanced manufacturing processes. This was demonstrated in the redesign of a thermoplastic liner for a Type IV hydrogen pressure vessel, where his DFM contributions enabled the development of a novel concept that successfully achieved the required 1575 bar pressure during hydrostatic burst testing.
PROCESS OPTIMISATION – Lewis has a strong aptitude for process optimisation, applicable across a range of manufacturing environments. He communicates ideas clearly and works effectively with operators, engineers, and senior stakeholders to secure buy-in when implementing improvements. This was demonstrated in a timber manufacturing environment, where his initiatives reduced the RDM (returns, damaged, missing) rate from 24% to 11% over a four-week period.
CAD & DRAWINGS – Lewis underpins his design work with advanced CAD modelling and technical drawing capability. He has extensive experience using SolidWorks and is adept at transitioning to new software, rapidly developing the required proficiency to deliver value to clients from the outset.
PROTOTYPING, TESTING & VALIDATION – Lewis has a strong R&D background, with extensive experience in prototype development, test programme execution, and design validation. He applies an iterative approach to refine and optimise solutions throughout the development cycle. This was demonstrated in the development of a self-heating air inlet system for a Tier 1 aerospace manufacturer, where his structured design and manufacturing approach resulted in a more efficient, repeatable production outcome.
ANALYSIS & DOCUMENTATION – Lewis supports his technical work with robust data analysis, using tools such as Excel, Python, and bespoke software to inform sound engineering decisions. This is complemented by thorough and structured documentation across all project stages, including risk management, decision tracking and technical reporting, ensuring clarity, traceability, and effective delivery throughout the project lifecycle.
PROJECT MANAGEMENT – Lewis has a proven track record of delivering multiple high-value projects across a diverse client base, adopting a customer-focused approach. He has extensive experience managing projects end-to-end, translating client requirements into structured projects that are executed and reported on within agreed timelines and budgets.

Caliber has experience in the Aerospace industry

Caliber Design has experience in the Biofuel industry

Caliber has experience in the Agriculture industry

PERSONAL STATEMENT

After completing a Master’s degree in Aerospace Engineering at The University of Sheffield, I began my career in a process engineering role within a fast-paced timber manufacturing environment. This is where I developed a strong foundation in design for manufacture, alongside a keen eye for process optimisation.

I then joined the Advanced Manufacturing Research Centre, specialising in the design and manufacture of composite parts and assemblies across the automotive, aerospace, defence, and energy sectors. I’ve worked on a wide range of projects, including high-pressure hydrogen storage tanks, self-heating aircraft inlets, high-speed permanent magnet rotors, and tidal energy blades. I particularly enjoy developing concepts from an early stage and identifying the most efficient ways to bring them into production.

Outside of work, I’m an avid runner, covering everything from 5 km to marathon distance (with an ultra potentially on the horizon), across roads, trails, and hills. I also enjoy spending time outdoors, whether that’s in the mountains, playing football or golf, or getting involved in any activity that gets me moving.

Project Experience

HVM CATAPULT

Advanced Hydrogen Pressure Vessel Development

Led the design and manufacture of a Type IV gaseous hydrogen pressure vessel for an automotive application. Key challenges included redesigning the sealing solution at the interface between the thermoplastic liner and aluminium boss, as well as developing and manufacturing a composite laminate capable of achieving the required strength for a 1575 bar hydrostatic burst test.

HERAEUS NOBLELIGHT

Flash Lamp Development

Developed, optimised, and validated a custom manufacturing process for the in-situ consolidation of thermoplastic composite materials. The process was successfully demonstrated on tubular and pressure vessel geometries using PA6, PP, and PEEK resin systems.

TIER 1 AEROSPACE SUPPLIER

Filament Wound Inlet

Supported the development of a novel self-heating air inlet component for a civil aircraft using a filament winding process. This involved advanced machine programming, process development, and precision machining to enable successful product realisation and meet performance requirements.

eRotor Sleeves

Led the development of a novel data acquisition process to quantify the prestress applied to carbon fibres during a high-tension filament winding process. This involved tooling design, modification of existing machine systems, and the implementation of data capture and analysis methods using fibre optic and conventional strain gauges.

MAGALLANES RENOVABLES

BLATEM

Led early-stage design and manufacturing development of a novel tidal blade production process. This approach utilised advanced composite materials, manufacturing techniques, and tooling design to achieve a lower-cost, more sustainable solution for tidal blade manufacture.

XCIENCE

HYTRANSTOR

Supported the design and manufacture of a conformable Type IV hydrogen pressure vessel aimed at improving volumetric efficiency within automotive drivetrain packaging.