QUALIFICATIONS
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BEng Tech (Mech) – 2017
SOFTWARE
Mechanical CAD Software
- Inventor (Autodesk)
- SolidWorks (Dassault)
Architectural / Structure CAD Software
- SAP2000
PDM/PLM Software
- Inventor Vault (Autodesk)
Analysis Tools
- Excel (for numerical method analysis)
- SolidWorks Simulation (Dassault)
ADDITIONAL LANGUAGES
- Malay (National language of Malaysia)
Samuel Bong
MECHANICAL ENGINEER
Skills Overview
Sam is a lifelong learner with a curious mind. He is experienced in machine and tooling design and has developed macros to automate frequent processes. Alongside this, Sam possesses a pragmatic approach to problem solving and is drawn towards innovative solutions. Sam also enjoys being in a team environment where he can coach and develop people to meet their full potential.
- TOOL DESIGN & ANALYSIS – Sam has experience with designing tooling used in the steel stamping and punching industry. Using FEA and hand-calculations Sam was able to look into how the tool would fail under various constraints and mitigate them in his designs. This experience gives Sam insight into creating robust tools with significant tool lifespan.
- DESIGN FOR FABRICATION & ASSEMBLY – Sam started out his career as a fabricator, this experience provides Sam with a real understanding of the limitations of manufacturing. Alongside this, his involvement in designing roll-forming machines provides him with the expertise in designing for assembly and maintenance.
- MACRO DEVELOPMENT – Sam’s desire to be efficient pushed him to learn and develop various macros to reduce the number of keystrokes during the generation of manufacturing drawings. Sam was also able to develop a data consolidation tool to manage Bill of Materials exports. As a result, Sam was able to share these macro tools with the team, improving their overall productivity.
- PROJECT MANAGEMENT & PROJECT ENGINEERING – Sam has worked in a fast-paced construction solutions environment. There he was able to develop key skills to effectively manage client and project expectations whilst providing design solutions within the scheduled timeline. Additionally, Sam has also worked in a collaborative environment alongside a range of departments as a project lead and lead engineer.
PERSONAL STATEMENT
Like most engineers, I’ve always had an innate desire to solve problems creatively and invent something that would benefit this world. And over the years, this desire developed into a hunger to learn and challenge myself. Alongside this, I am also drawn towards team environments which offers me the chance to support and encourage those around me. Engineering allows me to meets these desires and it provides me with a great opportunity to constantly be learning.
With regards to my background, I started my career as a Junior Fabricator, assisting in the production of architectural metalwork and bespoke furniture. Eventually, I moved into a Design Engineer role in the roll-forming forming industry gaining experience in machine and tooling design, where I refined my 3D CAD modelling and FEA skills. In addition to this, I have recently developed an interest in additive manufacturing and rapid prototyping.
Project Experience
Light Gauge Roll Forming Machines
These high precision machines were designed to form light gauge steel into framing and floor joists used in the construction industry. The production of these frames and floor joists served the purpose of increasing efficiency, productivity and reduces overall site waste when compared to traditional construction methods. I was part of the team that designed the newer generation of machines that are now used in construction businesses in 75 countries across the world. As a result of the ongoing sales of these machines, the team at Howick Limited won the 2019 Air New Zealand Cargo ExportNZ Export NZ Awards.
Swage Hole Tool
Developed a swage hole tool that perforates and forms a large swaged hole on the web of light gauge steel floor joists profiles. The complexity of the tool, was based around its requirement of having the capability of being positioned in multiple stages to accommodate for production runs and servicing mode.
Bridge Lance Tool
Designed a hydraulic powered tool that partially shears and deforms the web of light gauge steel profiles to form a ‘bridge lance’ profile.
Macro Development
Developed custom macros to automate drawing processes with the use of sheet templates, increasing the efficiency of generating production drawings.
Aluminium Stairs, Platforms, Walkway
Designed multi-level service access decking that supports gravity loads of HVAC ducting and units, mezanine access stairs for Watercare’s Mairangi Bay processing plant , 37 metre long walkway and stairtower for conveyor line access for Vissy Glass, platforms supporting HVAC units for North Shore Hospital, service walkway for cooling unit access for Silver Fern Farms, custom brackets and cantilever supports for Exxon Mobils Fuel Line walkway, cantilever supported stairs in a blast freezer for Maersk, 2 stage service platform for steam boiler access at Fonterra Eltham, caged ladders and walkways for the Waimea Dam site access and internal 3 flight stairs for Manawa Bay Premium Outlet Centre.
Macro Development
Developed a Bill of Materials Export Excel template macro for Monkeytoe, used for filtering out archived SKU and restricted codes, and calculating total quantities of recurring SKUs.
CANTERBURY SUSTAINMENT PROJECT
As part of the Canterbury Sustainment Project, I was seconded as a Senior Mechanical Engineer to support the long-term operational viability of the HMNZS Canterbury. My work focused on critical systems engineering, compliance, and design development, with a strong emphasis on stakeholder engagement and technical rigor.
Compressed Air System Upgrade
Led the engineering effort to improve the ship’s compressed air system by applying the Engineering Change Process to develop a comprehensive Design Solution Proposal. This was supported by investigative reporting, requirements collation, and formal design documentation, and presented to an Engineering Review Board comprising Navy leadership and Babcock staff. Additionally, the execution of a detailed design package for the starting air system, focusing on mitigating water contamination and enhancing reliability under marine operating conditions.
Sewage Treatment System Compliance & Market Research
Conducted a compliance study on MARPOL pollution regulations for sewage treatment systems, ensuring alignment with international maritime environmental standards. This was complemented by market research and consultation meetings to present compliant, cost-effective solution options tailored to operational and regulatory requirements.
Holding Tank Integration Study
Executed a technical estimate and feasibility study for the introduction of a holding tank system, including SME consultation and risk analysis to ensure safe integration and operational compliance.
Finite Element Analysis (FEA)
Conducted FEA simulations to assess structural performance of components under marine movement conditions, ensuring durability and safety.
Systems Engineering & Procurement Support
Applied systems engineering principles across multiple workstreams to support the development and integration of technical solutions. Contributed to procurement preparation through detailed market analysis and technical documentation, ensuring alignment with operational requirements. Additionally, supported trial planning and conducted ship class compliance studies to validate proposed system upgrades and ensure regulatory adherence.
PERSONAL PROJECTS
Curtain Robot
Designed a battery powered automated robot that opens and closes curtains. Developing this product gave me a greater understanding of battery management systems and how to select appropriate components.
Magneto Stirrer
Developed a handheld stirring device that uses magnetic coupling to mix and stir liquids in a beaker or cup. This project has allowed me to really test the limits of my 3D printers and fine tune its dimensional accuracy.
GOOD BUGGER AWARD
February 2024
Sam took out the Auckland award for his epic work at Monkeytoe. They were impressed with Sam’s questions, learning speed, innovation, and initiative. And Sam’s Client Summary Document is an exemplar of best practice.