Elia Haddad
Elia presenting capstone project at EnGenius2024

Elia Haddad

Mechanical engineer, Melbourne

I design automotive parts from measurement and 3D scan through CAD to manufacture, and carry design, process and reliability work in a steel rolling mill from the problem on the floor to installed, documented hardware.

eliahaddad234@gmail.com0490 668 256LinkedIn

Selected work

Product design and manufacture

Privately designed parts taken from measurement and 3D scan through CAD, iteration and manufacture.

SEC0002 assembly render: column shroud, base plate, hinged bracket and dash unit
Assembly: column shroud, base plate, hinged bracket and dash unit
SEC0002 dash bracket render: hinge lugs and dash mounting face
Dash bracket, hinge lugs and dash mounting face

Private commission · 2026

Digital Dash Retention Bracket

Toyota JZS171 Crown

Role Scoping, packaging measurement, design, prototyping

Problem
A Powertune digital dash normally goes into a JZS171 by cutting out the factory instrument cluster, which is not reversible.
What I did
  • Measured the packaging envelope off the car and modelled the column shroud and dash unit.
  • Designed a base plate that clamps to the column shroud and a bracket that carries the dash on a hinge line, so it swings clear of the cluster.
  • Printed fitment prototypes and revised the bracket against the car.
Result
Digital dash fitted with the factory cluster retained and readable. Fully reversible, with no cutting of the cluster, hood or column trim.
166 x 112 x 36 mmDash bracket envelope
116 x 50 x 44 mmBase plate envelope
SEC0001 console insert shell render, rebuilt from the processed 3D scan
Console insert shell, rebuilt from the processed 3D scan

SEC0001 · Private commission · 2026

Haltech CAN Keypad Console Mount

Toyota JZS171 Crown

Role 3D scanning, surface rebuild, design, print iteration

Problem
The centre console is a compound moulded surface with no drawing and no flat datum, so a keypad on a guessed profile rocks, gaps at the trim edge or ends up out of reach.
What I did
  • 3D scanned the console, processed the mesh in Blender and rebuilt the trim as solid CAD in Inventor.
  • Set the keypad position by reach and line of sight from the driving position.
  • Iterated the insert through seven printed revisions until the trim gap and keypad angle were right.
Result
A direct fit insert that drops into the ashtray aperture with no trim modification. The keypad sits flush to the console trim, and the factory ashtray insert can go back in.
207 x 104 x 58 mmInsert envelope
7Printed revisions
SL0002 rear subframe rear bush assembly, exploded render
SL0002 rear subframe rear bush assembly

SL0001 to SL0010 · Private product line · 2025 to 2026

SL Series Suspension and Intake Components

Polyurethane, printed and machined parts for Toyota and Lexus platforms

Role Design, material selection, costing, production and QC definition

Scope
Replacement parts designed around worn or unavailable OEM components: rear subframe bushes for the XE10 family, differential mount bushes and an intake adapter.
What I did
  • Modelled each part from the OEM bore, cup or flange it has to fit, and verified it against a donor before a batch.
  • Chose material for the duty: cast polyurethane or TPU 95A for compliance and NVH, aluminium sleeves for bolt clamp, PA6-CF or ASA for under bonnet heat and vibration.
  • Released each part with a bill of materials, a landed cost and a QC check on every unit.
Result
One subframe bush design covers twelve chassis codes across Toyota and Lexus, which is what makes the tooling and the batch worth doing.
Full breakdownComponent register · Materials and per unit checks · SL0001 and SL0002 fitment

Component register

SL0001 rear subframe front bush assembly, exploded render
SL0001XE10 family rear subframe, front bush82 dia x 206 mm, PU with alloy sleeve
SL0002 rear subframe rear bush assembly, exploded render
SL0002XE10 family rear subframe, rear bush102 x 295 x 102 mm assembly
SL0010 MR2 intake to 1G-FE throttle body adapter, render
SL0010MR2 intake to 1G-FE throttle body adapter115 x 115 x 40 mm, PA6-CF or ASA
SL0003 IS-F lower rear bushing, PU, renderPUSL0003 lower rear bushing, aluminium, renderAluminium
SL0003Lexus IS-F lower rear bushingPU and aluminium pair plus sleeve
SL0004 differential mount, outer, renderOuterSL0004 differential mount, inner, renderInner
SL0004Y38 differential mountTPU 95A or cast PU, 70 dia

Materials and per unit checks

PartMaterial and processCheck on every unit
SL0001Two piece polyurethane body on an aluminium sleevePress fit into the OEM cup, sleeve clamp under bolt load
SL0002Two piece polyurethane body on an aluminium sleevePress fit into the OEM cup, sleeve clamp under bolt load
SL0003Polyurethane and aluminium pair with a sleeveBore and shoulder fit to the subframe cup
SL0004TPU 95A printed at 100% infill, or two part PU cast in a printed former, optional aluminium crush sleevePress and shoulder fit to the diff cup, sleeve clamp, durometer against the NVH target, no walk out under load
SL0010PA6-CF or ASA, flange faces printed solid and surfaced, gasket both facesLeak down and vacuum hold, torque and re check after a heat cycle

SL0001 and SL0002 fitment

  • Lexus GS II S160 97-05
  • Lexus IS I XE10 98-05
  • Lexus SC II Z40 01-10
  • Toyota Altezza I XE10 99-05
  • Toyota Aristo II S160 97-05
  • Toyota Brevis JCG10/11/15 01-07
  • Toyota Crown XI S170 01-07
  • Toyota Mark II IX X110 00-04
  • Toyota Origin JCG17 00-01
  • Toyota Progres JCG10/11/15 98-07
  • Toyota Soarer IV Z40 01-05
  • Toyota Verossa X110 01-04

Industrial work

Industrial and heavy engineering

Structural access, rescue compliance, drive train modification and a reliability redesign at InfraBuild's Newcastle Rod Mill, each carried from the problem on the floor to installed hardware. I am now acting in a vacant Process Engineer role at InfraBuild's Laverton Rod Mill.

Every figure comes off the released drawing, the FEA study or the CMMS record.

Clarifier Basin Access Stair

No Twist Mill water treatment plant, Newcastle Rod Mill

Role Design and drafting, revision for construction, lift planning, install supervision

Jul 2025 to Feb 20266 drawings, A0

Problem
Every entry to the clarifier basin needed an EWP hire, roughly $20k a year. The basin edge is not level and there was no scope for a concrete footing.
What I did
Designed a drop in stair to AS1657 with an adjustable cantilever leg and forklift tyne pockets, so it levels on the uneven edge without civil works, and planned the four leg chain lift before the shutdown.
Result
Removed approximately $20k per year of EWP hire and returned about $10k on first use. Fabrication came in 25% under budget and design 40% under.
Full breakdownFigures · Standards
Total arrangement mass1 306.8 kg
Stair geometry4 risers at 215 mm, 750 mm inside width
LiftFour leg G80/G100 chain set, self locking clevis attachments
Weld inspection100% visual, 25% examined to AS1554.1 T6.2.2

Standards

  • AS1657
  • AS4100:1998
  • AS1554.1:2014
  • AS1101 Pt3
  • AS/NZS 3678:250
  • AS/NZS 3679.1:300
  • AS/NZS 1163
  • AS/NZS 4680
  • AS2700

Clarifier Bridge Rescue and Entry Modifications

Davit anchor point and step through ladder, Newcastle Rod Mill

Role Design, drafting, weld quality specification

Jul to Dec 20252 drawings, A0

Problem
The clarifier basin is a confined space with no rated retrieval point on the bridge, so entry could not be made compliant.
What I did
Designed a 3M davit floor mount into the bridge steel, raised the weld quality requirement to 100% MPI or LPI examination, and replaced the rung ladder with a step through ladder to AS1657.
Result
Rescue retrieval compliance achieved for confined space entry, and the climb now finishes at a protected step through rather than a rung.
Full breakdownFigures · Standards
Davit support2 x 250PFC, 10PL base
Anchor fixing4 x M20 through 22 dia, 50 dia spigot
Weld inspection100% visual, 50% examined, 100% MPI or LPI
Ladder4 rungs at 300 ctrs, 20 dia rod
BoltingM16 8.8 HT

Standards

  • AS1657
  • AS1554.1:2014
  • AS4100:1998
  • AS/NZS 3678:250
  • AS/NZS 3679.1:300
  • AS2700

East Roller Line DC to AC Motor Conversion

Reheat furnace roller line drive, Newcastle Rod Mill

Role Design, drafting, coupling sizing, shutdown install supervision

Nov to Dec 20251 drawing, A0

Problem
A new ABB induction motor replaced the DC machine, but its footprint, shaft height and coupling did not match the existing base.
What I did
Redesigned the base with new 20PL stiffeners and motor plate, sized the couplings, and added M16 jacking lugs so a fitter can align the motor in place instead of holding it on a crane.
Result
Conversion completed in the shutdown window with alignment achieved on the jacking lugs, and the as built drawing updated.
Full breakdownFigures · Standards
MotorABB TEFC 3ph, 3GBP 223 210-ADL
Base plate20PL, 4 holes 20 dia
Stiffeners20PL east and west, 348 deep
AlignmentM16 jacking lugs, 5 mm packers
BoltingAS1110 M16 x 80 8.8

Standards

  • AS4100:1998
  • AS1554.1:2014
  • AS1101 Pt3
  • AS/NZS 3678:250
  • AS1627.4
  • AS2700

Coil Unloader Car Detector Flap Redesign

Coil unloaders 1 and 2, Newcastle Rod Mill

Role Reliability redesign, 3D modelling and fit review, as built release

Feb 2025 to Jan 20265 drawings, A0 and A2

Problem
The coil detector flap's linear spring striker failed often enough to be a named contributor to unloader delay.
What I did
Replaced it with a torsion spring and bearing mounted gate, modelled in 3D before fabrication so fitment and maintenance access were resolved on the screen rather than on the car.
Result
Approximately $20k per year saved with payback under 14 months, and over four months in service without a delay attributed to the flap.
Full breakdownFigures · Standards
Torsion springASTM A401 chrome silicon, 0.8 kg
Bearings6009-2RS, internal circlip 75 nom
Gate wear plate11.6 kg, AS3678:250
Gate assemblies39.0 kg bottom, 38.3 kg top
Coil sensor arrangement138.7 kg

Standards

  • AS1100
  • AS1101
  • AS3678:250
  • AS3679.1:300
  • AS1443:1030
  • ASTM A401

Custom Roll Adjustment Spanner

FEA verified tool, design to release, Newcastle Rod Mill

Role Design, FEA and hand verification, release

Jun 2025Released with SAP BOM

Problem
Operators adjusted rolls with a tool that forced a poor posture and a high applied load, and no engineered replacement existed.
What I did
Designed a purpose built spanner, verified it by FEA and hand calculation, and took it through the full release including the SAP BOM.
Result
Manual handling risk removed at the source, with a verified, stocked and reorderable tool under change control.
Full breakdownFigures · Standards · Verification record, static stress studies, 5 Jun 2025
ReleaseFull design to release, SAP BOM
Factor of safety5, FEA and hand calc

Standards

  • AS1100
  • AS4100:1998

Verification record, static stress studies, 5 Jun 2025

StudyElementsNodesConvergenceWorst Jacobian
Initial geometry8 19314 5760.904%1.11
Revised geometry8 38215 0340.409%2.36
Coarse mesh check, h refined once6641 5161.51%1.96
Interim configuration8 30214 7830.518%1.12
Released configuration8 40414 9070.567%1.08

Contact

Elia Haddad

Mechanical engineer, B.Eng (Honours) in Advanced Manufacturing and Mechatronics.