Berke Caglayan
Charlottesville
Summary
Mechanical Design Engineer with hands-on experience leading full-cycle product development from concept to production in regulated, high-performance mechanical systems. Proven ability to design complex multi-component assemblies (40+ parts) with strong emphasis on reliability, precision, and manufacturability. Experienced working closely with manufacturing teams and suppliers to ensure design feasibility and production readiness. Demonstrated success reducing R&D costs by 85% through reverse engineering and efficient design strategies. Advanced SolidWorks user with strong assembly and mechanism design capabilities.
Overview
6
6
years of professional experience
1
1
Certification
Work History
Design Engineer
Zenith Firearms
Afton, VA
05.2025 - Current
- Led end-to-end design and development of a roller-delayed pistol platform (ZFP9), from concept through production release
- Designed and integrated 40+ precision mechanical components into a fully functional system
- Applied Design for Manufacturing (DFM) and Design for Assembly (DFA) principles to improve producibility and reduce design complexity
- Collaborated with machining vendors and internal manufacturing teams to ensure design compatibility with CNC machining and fabrication processes
- Defined material selection and surface treatments (heat treatment, anodizing, phosphate coating) to meet durability and performance requirements
- Achieved ~85% reduction in R&D costs by leveraging reverse engineering and minimizing prototyping iterations
- Developed detailed 3D models, assemblies, and technical drawings using SolidWorks with strong focus on fit, function, and tolerancing
- Iterated designs based on manufacturing constraints, tooling limitations, and assembly requirements
R&D Engineer
AKA Automotive
Bursa, Turkey
06.2024 - 02.2025
- Designed and developed structural automotive components for OEMs including Ford, Mercedes-Benz, and Hyundai
- Contributed to development of safety-critical components such as cross car beams, brake pedals, and subframes
- Created GD&T-compliant technical drawings and detailed BOMs for production release
- Managed engineering data and revisions using PLM systems (TeamCenter, SmartTeam, QMAD)
- Coordinated with validation teams to support mechanical testing and product verification
Engineering Intern
AKWEL Automotive
Bursa, Turkey
07.2023 - 09.2023
- Supported engineering team in CAD-based design reviews and prototype evaluations
- Assisted in benchmarking studies to compare design alternatives and improve component efficiency
- Participated in tolerance stack-up studies to support assembly fit verification
- Assisted validation activities during prototype testing and documentation review
Engineering Intern
CAGMAK Elevator
Bursa, Turkey
05.2020 - 09.2020
- Supported engineering team in the preparation of technical drawings and manufacturing documentation
- Assisted in the development process of hydraulic elevator components under senior engineer supervision
- Contributed to BOM preparation and design documentation updates
- Gained exposure to basic structural design considerations and engineering workflows
Education
Bachelor of Science - Mechanical Engineering
Karabuk University
Turkey01-2024
Skills
- CAD & Design: SolidWorks (Advanced), CATIA V5, AutoCAD
- Engineering: GD&T (ASME Y145), Tolerance Analysis, DFM/DFA, Mechanical System Design
- Tools: TeamCenter, SmartTeam, QMAD, MS Excel
- 2D and 3D modeling
- CAD software
- Creative thinking
Certification
- Certified SolidWorks Associate (CSWA) — Dassault Systèmes
- ASME Y14.5 GD&T — Lean Academy
- Applications in Engineering Mechanics — Georgia Institute of Technology
Languages
English
Professional Working
Turkish
Native or Bilingual
Timeline
Design Engineer
Zenith Firearms
05.2025 - Current
R&D Engineer
AKA Automotive
06.2024 - 02.2025
Engineering Intern
AKWEL Automotive
07.2023 - 09.2023
Engineering Intern
CAGMAK Elevator
05.2020 - 09.2020
Bachelor of Science - Mechanical Engineering
Karabuk University
ADDITIONAL INFORMATION
- Work Authorization: U.S. Green Card Holder
- Languages: English (Intermediate – Professional Working Proficiency), Turkish (Native)