Thomas Newberry

Thomas
Newberry

Product Designer & Mechatronics Engineering Student Transforming ideas into practical, manufacturable solutions.

I am a Mechatronics Engineering student with hands-on experience in product design, CAD modelling, prototyping, and manufacturing. I am passionate about solving real-world problems by designing products that make people's work easier, safer, and more efficient.

With experience designing and producing functional components for industrial applications, I combine mechanical design, additive manufacturing, electronics, and user-focused thinking to develop practical solutions from concept through to production.

Alongside engineering, my background in Communication and Digital Media enables me to clearly communicate technical ideas through documentation, visual design, and collaborative problem-solving across engineering and manufacturing teams.

Product Design Autodesk Inventor Rapid Prototyping Industrial Design Additive Manufacturing
CONTACT
PROJECTS & EXPERIENCE
PROJECTS
WORK

Autonomous Transport Platform — Product Design & Rapid Prototyping

University of Newcastle Warman Design & Build Competition · 4th Place
  • Developed an autonomous transport platform from initial concept through to functional prototype, solving the challenge of collecting and transporting objects across unstable terrain.
  • Created mechanical designs, CAD models, and manufacturing drawings for custom chassis components, linkages, and end-effectors while considering assembly requirements and material selection.
  • Applied Design for Manufacture (DFM) principles using 3D printing and laser-cut fabrication methods to create lightweight, functional, and reliable components.
  • Conducted design reviews, risk assessments, and iterative prototype testing to identify failure points and improve system performance throughout development.
  • Integrated mechanical systems with embedded control to coordinate movement, stability, and actuation within the autonomous platform.
  • Achieved 4th place overall at the University of Newcastle Warman Design & Build Competition, demonstrating effective teamwork, problem-solving, and engineering execution.
Product Development Mechanical Design CAD Modelling Inventor Mechanical Systems

Autonomous Mobile Robot

University Project — Embedded Control, Sensors & Track Navigation
  • Designed and built a small-scale autonomous vehicle to navigate a predefined track with curves and obstacles without manual input.
  • Integrated sensors (line tracking / proximity) with a microcontroller to detect the course, stay on path, and make real-time steering and speed decisions.
  • Implemented and tuned control logic to balance speed and stability, focusing on consistent lap times rather than one-off “lucky” runs.
  • Worked in a small team to plan tests, debug issues under time pressure, and document results so others could understand and repeat the setup.
  • Developed a reliable autonomous system by combining mechanical design, embedded programming, and iterative testing to improve performance and user confidence.
Embedded C++ Control Systems Sensors Autonomous Navigation

Integrated Smart Speaker & Ambient Lighting System

Personal Product Development Project — ESP32, Bluetooth Audio & User Experience Design
  • Designed and developed an integrated entertainment system by combining Bluetooth audio, wireless lighting control, and embedded electronics into a single user-focused product.
  • Engineered an ESP32-based controller to synchronise addressable LED lighting with live audio, creating an immersive and responsive user experience.
  • Integrated multiple existing technologies into one reliable system, resolving compatibility, timing, power distribution, and signal interference challenges throughout development.
  • Designed an intuitive user interface and operating modes that allowed non-technical users to operate the system with minimal setup.
  • Applied iterative prototyping, testing, and refinement to improve reliability, usability, and overall product presentation.
Product Development ESP32 Systems Integration User Experience Rapid Prototyping

Hushpak Engineering | 3D Printing Technician

Industrial Additive Manufacturing
  • Collaborated with engineers and production staff to develop practical solutions for customer-specific applications.
  • Designed and refined functional products and components using Autodesk Inventor, balancing performance, manufacturability and cost.
  • Produced prototypes and production-ready components using industrial additive manufacturing equipment.
  • Worked across design, manufacturing and testing to rapidly iterate products from concept through to final production.

HVCCC | Stockpile Planner

Newcastle CBD
  • Managed and optimised logistics workflows in a fast-paced, high-pressure industrial environment.
  • Applied strong analytical and problem solving skills to maintain efficient coal chain scheduling and operational flow.
  • Collaborated with multiple teams and external stakeholders to deliver accurate, reliable, and time-critical outcomes.
  • Developed resilience, attention to detail, and clear communication skills, directly transferable to engineering and manufacturing environments.

LOVE REALTY | Marketing Consultant

Boolaroo
  • Designed and delivered targeted digital campaigns, demonstrating clear communication and structured planning.
  • Produced multimedia content to support branding initiatives, requiring creativity, organisation, and technical execution.
  • Worked effectively within a team to meet strict deadlines, strengthening collaboration and project coordination skills.
PROFILE
SKILLS
ABOUT

Product Design

  • Concept development, ideation, and iterative design refinement for practical real-world solutions.
  • User-focused design approach balancing functionality, aesthetics, safety, and manufacturability.
  • Experience developing products from early concepts through CAD modelling, prototyping, testing, and refinement.
  • Strong interest in creating products that improve how people work and interact with technology.

Mechatronics & Embedded Systems

  • Embedded systems development using Arduino and ESP32 platforms.
  • Integration of sensors, actuators, motors, and control systems for automated solutions.
  • Stepper, servo, and DC motor control with practical electronics troubleshooting.
  • PCB prototyping, soldering, wiring, and circuit simulation using LTSpice.

CAD & Engineering Design

  • Fusion 360, Inventor, Creo, Revit, and Granta EduPack across mechanical design projects.
  • Experience with GD&T, sheet-metal design, plastic part modelling, and engineering drawings.
  • Designed components with consideration for tolerancing, assembly, materials, and manufacturing requirements.
  • Managed CAD data through revision control workflows

Manufacturing & Prototyping

  • Professional experience in 3D printing and rapid prototyping for industrial applications.
  • Design for Manufacture (DFM) and Design for Assembly (DFA) principles applied to product development.
  • Experience with additive manufacturing, laser cutting, prototype validation, and design iteration.
  • Applied structured problem-solving, iterative testing, and design refinement to improve product reliability and manufacturability.

From Concept to Creation

I enjoy taking products from an idea through design, prototyping, testing and refinement. Whether it's developing autonomous robots, industrial components, or embedded electronic systems, I'm motivated by solving practical engineering problems that improve the way people work.

This portfolio shares some of the projects I’ve designed, built, and tested.

Alongside engineering, I also have a background in communication and digital media. This allows me to approach projects from both the technical and user experience perspective, creating solutions that not only work, but make sense to the people who use them.

If you'd like to know more about any project, feel free to reach out. I’m always happy to discuss the design process, challenges faced, and what I’m working on next.