About Molds & Dies

EngD. Mohamed Aboelfotouh is a highly experienced Industrial and Mechanical Design Engineer with a deep-rooted passion for manufacturing excellence. With a career spanning over two decades, he has led the design and development of hundreds of plastic injection molds, sheet metal dies, high-pressure die casting tools, and specialized jigs and fixtures.

A strong advocate for Design for Manufacturing (DFM), Mohamed brings together theoretical expertise and shop-floor practicality to create solutions that are both efficient and reliable. His work emphasizes manufacturability, cost-effectiveness, and streamlined production, making him a trusted name in the field.

Mohamed’s extensive background in mold and die design is matched by his dedication to sharing knowledge and supporting fellow engineers through open resources, hands-on tutorials, and calculated design tools.

The content on Molds-Dies.com reflects his mission to bridge the gap between design theory and production reality—empowering others to build better, smarter, and more efficient tools.

Qualifications and experience

• PhD in industrial and mechanical design engineering, Cairo University (2018).
• Master's degree in Lean Six Sigma.
• More than 20 years in mold, die and tooling engineering: design, manufacturing and tool-room management.
• Hundreds of tools designed and brought into production: plastic injection molds, sheet metal dies, high-pressure die casting dies, extrusion dies, jigs and fixtures.

Areas of expertise

• Plastic injection mold design.
• High-pressure die casting (HPDC).
• Sheet metal dies.
• Aluminum extrusion dies.
• Design for Manufacturing (DFM), machining and cost-effective tooling.
• Lean Six Sigma: process improvement, waste reduction and quality control in tool-making and production.
• Management: leading tool-room and tool factory operations, engineering teams and projects.

Editorial approach

Every article, calculator and troubleshooting guide on Molds & Dies is written and reviewed by Mohamed, based on his design and shop-floor experience and on the standard engineering references of each process. The calculators use the published engineering formulas shown on each page, so you can follow and check every result. Their results are a starting point for design: always confirm them against your machine, material and process data.

Found an error, or have a question about an article? Please contact us — corrections are reviewed and the article is updated.