Bjorn Rohwer

Truck Bed Cargo Brackets & Custom Vehicle Mounts

Knaus Tabbert AG • Part time

Aug 2026 - Sep 2026 • 1 mo

My work focuses on developing CAD models for custom vehicle accessories, cargo mounting components, equipment brackets and practical mechanical attachment systems. A typical challenge occurs when a new accessory must fit an existing vehicle without interfering with body panels, storage access or factory mounting features. The initial concept may also lack sufficient information about fastening locations, component clearances and intended loads. I approach these projects by reviewing the vehicle reference geometry, measured mounting points, installation requirements and expected use. Using SolidWorks, I develop 3D models of mounting brackets, cargo supports, accessory adapters and related assemblies. When the proposed geometry creates interference or installation difficulties, I revise the mounting arrangement and refine the component dimensions to improve fit and assembly access. I also consider material choice, fastening methods and manufacturing limitations during the design process. Deliverables can include editable CAD models, STEP/STL files, assembly views and technical drawings for prototype and supplier review. Load ratings and road use suitability require engineering assessment and physical testing.

Injection Molded Plastics & Ergonomic Tool Handles

Röchling • Freelance

May 2026 - Jun 2026 • 1 mo

I specialize in functional plastic product design, ergonomic tool-handle geometry and CAD modifications intended to improve prototyping and manufacturing feasibility. One common problem during product development is that an initial concept has attractive surfaces but contains thin walls, difficult-to-mold features, sharp transitions or fastening details that are not suitable for the intended process. A tool handle may also need changes to its grip shape, component interface or assembly arrangement. My approach begins with reviewing the product's intended function, material, manufacturing method and critical measurements. Using SolidWorks, I develop controlled 3D geometry and evaluate features such as wall thickness, draft, ribs, bosses, fillets and component alignment. When a design presents possible manufacturing issues, I identify the affected areas and propose practical CAD modifications while preserving its intended function and overall appearance. I prepare editable SolidWorks models, STEP/STL exports, technical drawings and design review views. The aim is to support product refinement and clearer supplier communication, with final tooling and production approval completed by the manufacturer.

Automotive Headlight Tabs & Replacement Parts

HELLA • Part time

Mar 2026 - Mar 2026 • 0 mos

My focus is the reconstruction and modification of automotive plastic parts, particularly mounting tabs, small brackets, retaining features and components that are damaged or no longer available in their original form. A recurring challenge in this type of work is that the original component may be broken, leaving only partial geometry, photographs or measurements. Without accurate mounting positions, even a visually similar replacement can fail to fit the surrounding assembly. I begin by reviewing the available references and identifying critical features such as mounting-hole centers, tab thickness, attachment geometry and contact surfaces. Using Fusion 360, I rebuild the component as a clean 3D CAD model, paying attention to functional dimensions rather than simply copying the damaged appearance. When the replacement requires better fit or reinforcement, I review the proposed changes against the available installation information. The resulting deliverables can include editable CAD, STEP/STL exports, dimensional views and prototype recommendations. The goal is to provide a practical reconstruction for inspection and test fitting. Vehicle compatibility, material performance and safety-related applications require separate validation.