I design it. I build it.
I prove it.
Then I help you scale it.
Mechanical design, tooling and fixtures, inspection, and the software that ties them together. I am a USAF veteran with 15 years on production floors and in engineering offices. I consult, I contract, and I build products of my own.
Race subframe in. Everything else needed a home.
Tail extension, rectifier bracket and ECU tray for my ASRA club race R1 on a Moto Holders race subframe. Modeled in Inventor, test fit with printed parts, then cut, formed and bolted on. If you are building a race bike and need brackets that fit the first time, this is the work I do.
Quoted it in billet. Then redesigned it for printed metal.
Passenger peg extension brackets for a riding school's Yamaha MT-10 fleet. Same bolt pattern and mating faces, topology optimized, checked in FEA, about 30% lighter than the billet part and quoted for production in printed aluminum.
Air to the caliper. Hung off two bolts.
A brake cooling cowl for my Panigale V4 that clamps under the caliper mount bolts. Modeled in Inventor around the real rotor and mount, printed, test fit on the bike, then run through CFD to see where the air goes.
Product design and reverse engineering.
Client: Driveway LabsSupra GT door pull
3D scanned the factory door pull and replaced it with a printed frame and pull mechanism, carbon face plate, titanium hardware and five strap colors.
See the build →Modular TIG torch handle
A ducted core and a threaded diamond-knurl grip sleeve for WP-17 and WP-26 torches, with fit-check coupons and a full print pack.
See the build →Pick your door.
Need a fixture designed, a part made buildable, or first articles inspected?
I have designed press dies, robot cells and metrology systems, and I still work the production floor every week.
Veteran-owned and registered in SAM.gov.
Six years maintaining weapons and aircraft in the Air Force taught me to build to the spec. I am also developing drone and field equipment for first responders.
I race, so I built the tools I wanted at the track.
Corner IQ turns your RaceBox or AiM data into a debrief you can use between sessions. I also design and build race parts, like the tail bracket set on my club R1.
What I do
Very few independent engineers have done all four. I have, and you work with me directly from the first call to the final drawing.
Design
01- Production parts and assemblies in Inventor and SolidWorks
- Die cast and sheet metal housings, released to production
- Jigs, fixtures, gauges, press dies
- Drawing packages to ASME Y14.5, iLogic-automated
Build
02- CNC programming and machining background
- Robot cells and automation layout
- Rapid prototypes in-house
- Local shop network I manage for you
Prove
03- First Article Inspection plans and reports
- CMM and probe metrology experience
- Scan-to-CAD and deviation maps
- Materials and failure testing background
Scale
04- Work instructions and standard work
- CAD templates and automation
- Shop-floor software and dashboards
- Product IP taken from prototype to production
CAD that a vendor can build from.
I model parts for the way they get made. Cast, machined, formed, molded or printed, one-off or production. I have built the dies, run the machines, inspected the parts and taken products from first sketch through tooling and launch, so the CAD comes out ready to quote, build and check.
- Parametric part and assembly modeling
- Die cast, sheet metal, molded, and machined DFM
- Drawing packages with GD&T to ASME Y14.5
- Reverse engineering from scans and samples
- CAD automation: iLogic, templates and scripts
- Vendor tooling reviews and first article approval
Selected work
Motorsport // Sheet MetalYamaha R1 Tail Bracket Set
Tail extension, rectifier bracket and ECU tray for my ASRA club race R1 on a Moto Holders race subframe. Modeled in Inventor, test fit with printed parts, then cut, formed and bolted on. Render shows the parts from the production CAD on a phantom frame built from photos.
Design for Metal AM // Topology OptimizationMT-10 Peg Extension Bracket, Redesigned for Metal AM
A billet passenger peg extension bracket for a riding school's MT-10 fleet, redesigned for 3D printed metal. Same bolt pattern, topology optimized on three load cases, checked in FEA, about 30% lighter, and quoted for production next to the CNC version.
Motorsport // Aero & CoolingDucati Panigale V4 Brake Cooling Cowl
A bolt-on front brake cooling cowl for my Panigale V4. A scoop beside the axle feeds a swept duct to the caliper, and the cowl clamps under the caliper mount bolts. Modeled in Inventor around the rotor and mount, printed, test fit, then checked with CFD.
Product Design & DFAMModular TIG Torch Handle, Prototype P1
A 3D-printed modular handle for WP17 and WP26 TIG torches: 5.00 in long, 1.500 in over a diamond knurl, with internal air ducts that pull cooling air from windows at the head to the tail. Two sleeve builds, print pack and assembly instructions released.
Reverse EngineeringMKV Toyota Supra GT Door Pull
Reverse engineered the factory MKV Supra door pull from a 3D scan, then designed a new 3D printed frame and pull mechanism with a carbon fiber face plate, titanium hardware and five strap colors.
Sheet Metal & DetailingDSPro Wash Bucket & Detailing Accessories System
Sheet metal detailing accessories for DSPro: a bottle rack that hangs on a 5-gallon bucket rim, a laser-cut Mk2 grit guard, and a wall bottle rack.
I also build my own products.
Consulting keeps me sharp. Building my own products keeps me honest about what it takes to get something to market. If you want to pilot, partner, or license, I would like to hear from you.
See what I am building →Corner IQ™
Telemetry and session debriefs for track riders and drivers. Import RaceBox or AiM data and get answers between sessions.
Try it with your own CSV, no signup →IN DEVELOPMENTFirst responder drone program
Drone and field equipment built around how fire, EMS and police crews actually work. Looking for pilot agencies.
Engineer, veteran, racer.
I started in the Air Force maintaining weapons and aircraft. Since then I have worked almost every step of how a part gets made and proven: CNC machining, CMM inspection, composites testing, press dies, robot cells, and metrology systems built into the machine.
Today I take LED lighting products through the full commercial lifecycle as a Senior Product Engineer, and I write my own software to do it faster: AI agents, custom documents, data dashboards and process programs. I race, and a lot of my own projects start at the track. Kind of a Big Dill is my own shop, where all of that goes to work on your idea.
And yes, the name is a joke. The work is not.
Read my story →Simple and direct.
Send it over
Drawings, STEP files, photos, or just a description of the problem.
I review it
I read every request myself and reply within 2 business days.
Fixed quote
A clear scope and price before any work starts. No surprises.
Work and handoff
Native CAD, drawings, reports, and a short note on anything your vendor will ask about.
In their words
“Kind Of A Big Dill did an amazing job designing and 3D printing customized products for our business. They took their time understanding who we were and tailored everything to match our branding and clientele. Us and our customers love the unique products not able to be found elsewhere!”
“I have been working with Dillon for several years on projects in automotive, manufacturing, automation, drones, and as well with my own professional development utilizing Solidworks and other industry programs. I wouldn't have been successful in many things without him, and he has become a lifelong asset and teammate.”
Tell me what you are working on
A drawing, a problem, or a rough idea is enough to start. I read every request myself and reply within 2 business days.