Having graduated from Imperial College with MSC/DIC in Composites Materials, Feras has spent 9 years working for the largest Wind Turbine Company in the world, where he was employed as Blades Tooling Specialist and the Tech Lead for blades lifting & assembly within blade production engineering business unit. During his time in the wind industry, Feras has successfully led the development, design, manufacture and commissioning of more than 15 serial production lines of blade shells, internals, lifting and assemblies in Denmark, Spain, Italy, UK, USA, China, Germany and Brazil.
The highlight of Feras’s career was being the lead tooling engineer and project manager on one of the largest blade shell moulds in the world. At +80m long, +70tonnes in weight, it was the first ever serial production shell mould in the world equipped with double-hinge technology and reduced turning height. The mould is currently operational in Europe.
“I believe that Blades tooling is still a young industry, and there is globally a strong demand for reliable mould suppliers, that can deliver technically robust moulds at competitive prices. CAPEX and OPEX reductions are key to all blades manufacturers, and has a direct effect on the cost of energy.
Habitually, tooling requirements specifications do not exist or are over complicated, which to some extent increase the cost of the moulds. Good understanding of product design, and manufacture process is fundamental to the delivery of a good mould.
At DFS Composites, we do not copy paste, we follow a six sigma approach to gather the voice of the customers which we translate into customer’s requirements specifications, which subsequently initiate our design phase."