At Alpha Manufacturing, innovation begins with our talented Engineering team – a group of problem-solvers who transform ideas into real-world solutions. From concept to production, they play a vital role in ensuring each product is both brilliantly designed and built for manufacturability.
We sat down with them to get a behind-the-scenes look at what they do, what drives them, and what they enjoy about being part of the Alpha Manufacturing team.
Darran Cassar – Engineering Manager
With an impressive 20-year journey at Alpha Manufacturing, Darran’s experience spans programming, design, and now leadership as Engineering Manager. Since COVID, he’s led the team with a hands-on approach, still actively involved in engineering while managing a wide portfolio of products.
“I still love getting stuck in with the technical side. Even as a manager, there’s something special about solving an engineering puzzle and helping steer customer designs to fit our capabilities.”
Darran is especially proud of his involvement in projects like Cubbie, the personalised sensory space, a product he’s passionate about both technically and personally. “I visited a school in London where a Cubbie was installed – it was amazing to see something we built making such a real-world impact.”
Outside of work, you’ll find Darran tackling home improvement projects or spending quality time with his family – who funnily enough also all work here at The HEX Group!
Matt Carr – NPI/Design Engineer
Matt has been with Alpha Manufacturing for over nine years, starting in New Product Introduction (NPI) and growing into a design engineer role. He works closely with the Sales team, developing brand-new customer concepts and transforming them into practical, manufacturable products.
“What I really enjoy is taking something completely fresh from a customer, and reshaping it into something that can actually be built. That’s where the challenge lies, and it’s incredibly rewarding.”
Matt’s day-to-day involves tools like SolidWorks, CAD, and Radan for programming and design. He’s also deeply involved in tooling and fixture design to support smooth production. No two days are the same, especially when working with diverse customers and products like electrical cabinets.
When he’s not solving design challenges, Matt enjoys exploring the Staffordshire countryside with his dog, and spending time with his family outdoors.
Leo Manifold – Trainee Production Engineer
Leo is the newest addition to the team, joining in September 2023 as a degree apprentice while studying BEng Manufacturing Engineering at the University of Derby. But his Alpha Manufacturing journey began earlier – back in 2021, during a two-week work experience that sparked his passion for engineering.
“When I did my work experience, I was completely drawn in by everything that was possible here. Now, even as an apprentice, I get to take ownership of real projects. It’s amazing to feel so trusted and supported.”
Leo’s role bridges the gap between design and production, using CAD, SolidWorks, and Radan programming tools. He enjoys the freedom, responsibility, and variety in his role, and has been working on projects like Cubbie, under Darran’s mentorship.
As one of The HEX Group’s apprentices, Leo is also gearing up for the Tough Mudder challenge this July in support of Race Against Blood Cancer. When he’s not engineering, you’ll likely find him running, kickboxing, or snowboarding.
Evan Sutton – Engineering Technician Apprentice
Now in the final stretch of his third year as a Level 3 Engineering Technician apprentice, Evan has completed rotations across all areas of Alpha Manufacturing, from Punch and Laser to Planning and Engineering. These experiences helped him discover a love for design and problem-solving.
“I’ve always enjoyed the hands-on side of engineering. GCSE Engineering really got me hooked. The rotations have been brilliant for meeting people and finding out what suits me.”
Recently moved into a full-time role in the Engineering team, Evan has become confident using SolidWorks and is already contributing to key projects. He works closely with Leo, helping design stillages, which are custom fixtures that support products through manufacturing and transport. He’s also hands-on building Cubbies, bringing customer solutions to life.
Inspired by his brother’s apprenticeship, Evan chose to go straight into work rather than university. He’s excited about gaining more responsibility and continues to grow in both confidence and capability.
Outside of work, Evan helps his dad with wedding DJ gigs, enjoys socializing with friends, and is looking forward to the next phase of his engineering journey.
Looking Ahead
Our Design Engineering team is the heart of innovation at Alpha Manufacturing. Whether it’s creating custom solutions, optimising designs, or pushing the boundaries of what we can produce, this team brings passion, precision, and creativity to every challenge.