RAFAEL ALVES
St. Petersburg
Summary
Dynamic Product Development and Mechanical Design professional with over 10 years of specialized experience in sheet metal engineering, SolidWorks 3D modeling, and CNC manufacturing. Expertise includes delivering thousands of custom parts and assemblies for CASE New Holland (CNH), consistently adhering to stringent automotive quality standards such as GD&T, APQP, and FMEA. A robust hands-on background in 5-axis CNC programming, nesting, and factory support complements a proven track record in managing full product lifecycles and optimizing manufacturability through effective collaboration with cross-functional teams. Bilingual in English and Portuguese, enhancing communication in diverse work environments.
Overview
17
17
years of professional experience
Work History
MASTER CNC PROGRAMMER
Tampa Bay Marble and Granite
07.2023 - Current
- Program and nest complex 2D and 3D parts for CNC Denver 5-axis machines, applying GD&T principles and utilizing SolidWorks for geometric modeling when required. Operate advanced tooling including finger bits and suction cups, as well as manual templates, to execute intricate geometries, miter cuts, and vein matching across a variety of materials such as porcelain (¼", ½", ¾"), quartzite, engineered stone, and marble. Create and manage layouts directly on the machine interface and in CAD environments to ensure optimized material usage and precision. Oversee preventive maintenance tasks such as tool changes, blade replacements, lubrication, and general upkeep to maintain peak machine performance. Ensure consistent production flow and quality control by managing complementary cuts and making real-time adjustments on the shop floor.
- Developed CNC programs for intricate stone cutting and shaping operations.
SENIOR CNC PROGRAMMER
Alpha Granite and Marble
02.2022 - 06.2023
- Operated and programmed the Donatoni Jet 500 5-axis CNC machine, applying GD&T standards and CAD/CAM techniques for precise execution of intricate stone-cutting projects. Leveraged advanced capabilities such as finger bit tooling and vacuum suction systems to perform complex cuts, shape geometries, and reposition heavy slabs efficiently. Produced high-end surfaces with accurate miter joints and seamless vein matching across materials including porcelain (¼", ½", ¾"), quartzite, engineered stone, and natural marble. Utilized SolidWorks and native machine software to generate 2D and 3D layouts tailored for optimal nesting and reduced material waste. Supported continuous workflow by monitoring production sequences and assisting with real-time problem-solving during secondary or complementary cuts. Performed routine maintenance tasks including calibration, blade/tool replacement, and system greasing to ensure machine reliability and consistent output.
- Conduct routine maintenance on CNC equipment to ensure optimal performance.
CNC PROGRAMMER
Plazza Natural Stone
05.2021 - 01.2022
- Programmed and operated the Donatoni Jet 625 5-axis CNC machine, utilizing GD&T principles and CAD layouts to execute detailed fabrication of stone components. Worked extensively with finger bit tooling to achieve smooth radius details and precise geometries, while using suction cup systems to manage slab positioning during cutting cycles. Performed mitered cuts, book matched veining, and high-precision finishing across various materials including porcelain (¼", ½", ¾"), quartzite, engineered stone, and marble. Developed optimized cutting paths and nesting strategies using both the machine's built-in interface and SolidWorks for custom 3D parts. Ensured production consistency through careful supervision of complementary cuts and in-process adjustments. Conducted proactive maintenance such as tool changes, blade replacements, and machine lubrication to sustain full operational efficiency and minimize downtime.
CNC PROGRAMMER | 2D & 3D CAD DESIGNER
Dushi Marble & Granite
05.2019 - 05.2021
- Programmed and operated the Breton Combicut 5-axis bridge saw with integrated waterjet, one of the most advanced machines in the industry. This high-end equipment features precision suction cups and waterjet cutting at over 60,000 PSI, requiring not only exceptional technical skill but also an engineering-level approach to analysis, process control, and machine logic. Responsible for programming detailed cutting paths with full respect to operational sequences and tooling requirements, ensuring smooth performance and avoiding costly errors. Created both 2D CAD layouts and 3D part models using AutoCAD and SolidWorks, providing visualization, accurate dimensions, and efficient nesting strategies. Supported high-end fabrication demands with exacting standards for design clarity, miter precision, and vein matching. Regularly managed complementary cutting processes while monitoring material flow and overall production output. Handled preventive maintenance including nozzle replacements, blade changes, and feed control, and troubleshooting minor mechanical issues, keeping the machine operating at peak performance with minimal downtime. Additionally, gained cross-training and operational experience with the Eura bridge saw (1 year) and Park Industries Yukon 2 bridge saw (4 months), enhancing adaptability and machine knowledge across multiple platforms.
PRODUCT DEVELOPMENT ANALYST
Lafaete Locação
01.2012 - 08.2013
- Led the design and development of large-scale modular infrastructure projects across Brazil’s mining, civil construction, and oil & gas sectors. Most notably, directed the full engineering and execution of the Ferro Carajás S11D project for Vale (Vale do Rio Doce)—a $27 million initiative involving the creation of 927 livable container units, the largest and most valuable project ever delivered by the company at the time. Used SolidWorks for 3D mechanical modeling and AutoCAD for 2D architectural layouts, producing detailed technical drawings compliant with regulatory standards including NR18, NR10, and NR24. Standardized layout templates, implemented quality control methodologies, and optimized design processes for increased efficiency and consistency. Worked with high-profile clients such as Petrobras, Gerdau, Usiminas, Engevix, Construcap, and OEC (formerly Odebrecht), delivering tailored prefabricated solutions that met demanding industrial requirements. Conducted market research and technical analysis to source international container and equipment solutions, and oversaw the assembly of new modular units for deployment across job sites. Additionally, provided technical training and delivered presentations to multidisciplinary teams across various company branches, ensuring clear understanding of standards, procedures, and product specifications. Promoted from Designer (Jan 2012 – Jul 2012) after contributing to the development and standardization of internal architectural layout practices.
- Watch Company Video – https://www.youtube.com/watch?v=W4vydhiRlBs
PRODUCT DEVELOPMENT ENGINEERING ANALYST
CEMAÇO
03.2011 - 08.2011
- Oversaw the Product Development Engineering department, coordinating and supervising the design and production of new components primarily derived from sheet metal. Utilized SolidWorks for 3D modeling and 2D detailing to generate technical documentation and support the downstream demands of production planning (PCP), manufacturing, and quality control. Supported every stage of production with process sheets, quality control plans, and compliance documentation. Engineered medium and heavy-duty components serving the naval, oil & gas, and heavy machinery industries, often involving complex fabrication requirements. Developed custom templates, jigs, gauges, PNP devices, and fixtures to ensure precision in various manufacturing processes including plasma and oxy-fuel cutting, chamfering, bending, calendering, welding, machining, and custom rack assembly. Defined and implemented methodologies and strategies for a multidisciplinary team, introducing continuous improvement initiatives and conducting detailed analysis and review of both product structures and process flows. Led cost estimation and pricing, using material nesting and flat patterns developed in SolidWorks to calculate manufacturing feasibility and margins. Served as the technical lead for approval of quality and production documentation, ensuring standards were met across all phases of development.
- Watch Company Video – https://www.youtube.com/watch?v=XTtb8ga7uqw
DEVELOPMENT ENGINEERING ANALYST
Ferrosider Group
01.2009 - 01.2011
- Progressively advanced through engineering roles—Intern, Trainee Technician, and finally Development Analyst—within a major steel and industrial components manufacturer. Worked across departments to deliver product development, prototyping, and process engineering solutions for the automotive, naval, oil & gas, and steel sectors. Specialized in the design and development of mechanical parts and tooling for light, medium, and heavy-duty applications. Created precision jigs, masks, PNP devices, custom fixtures, and structural components using 2D and 3D parametric CAD software, ensuring functionality and manufacturability. Gained deep exposure to cutting-edge manufacturing processes, including laser, plasma, and oxy-fuel cutting, calendering, chamfering, welding, machining, and assembly line optimization. Collaborated with cross-functional teams to coordinate samples, run feasibility studies, and define technical strategies for leaner production and continuous improvement. Conducted product structure analysis and guided cost estimation based on materials, cycle times, and development data. Acted as the responsible technician (RT) for the approval of production and quality control documentation.
- Watch Company Video - https://www.youtube.com/watch?v=rCVyBtSwuWg
Education
Bachelor of Science - Mechanical Engineering
PUC / Newton Paiva University
Belo Horizonte, Brazil07-2008
Skills
- Fluent in Portuguese and English
- SolidWorks 3D modeling and AutoCAD 2D drafting skills
- Sheet Metal Design, Flat Patterns, Assembly Modeling
- Laser, Plasma, Oxy-Fuel Cutting, Chamfering, Bending
- Welding, Calendering, Machining, Custom Fixtures
- CNC Programming (5-Axis: Donatoni, Denver, Breton, Park)
- Nesting, Toolpath Optimization, Vein Matching, Mitering
- Materials: Sheet Metal, Granite, Marble, Engineered Stone
- Product Development: Concept to Production, GD&T, BOMs
- Modular Housing & Container Design
- Production Planning, Process Sheets, Methodologies
- Team Coordination, Cross-Functional Collaboration
- Cost Estimation, Pricing Surveys, Design-to-Cost Strategy
- Technical Training, Standardization, Documentation Approval
- Continuous Improvement, Root Cause & Dimensional Analysis
- Industries: Mining, Oil & Gas, Civil Construction, Naval
Languages
English
Native or Bilingual
Portuguese
Native or Bilingual
Timeline
MASTER CNC PROGRAMMER
Tampa Bay Marble and Granite
07.2023 - Current
SENIOR CNC PROGRAMMER
Alpha Granite and Marble
02.2022 - 06.2023
CNC PROGRAMMER
Plazza Natural Stone
05.2021 - 01.2022
CNC PROGRAMMER | 2D & 3D CAD DESIGNER
Dushi Marble & Granite
05.2019 - 05.2021
PRODUCT DEVELOPMENT ANALYST
Lafaete Locação
01.2012 - 08.2013
PRODUCT DEVELOPMENT ENGINEERING ANALYST
CEMAÇO
03.2011 - 08.2011
DEVELOPMENT ENGINEERING ANALYST
Ferrosider Group
01.2009 - 01.2011
Bachelor of Science - Mechanical Engineering
PUC / Newton Paiva University