Engineering Sustainable Innovation: How Michael Belhassen's Mechanical Engineering Expertise Transforms Manufacturing Processes

By- Evelyn hall

Manufacturing efficiency and environmental responsibility often seem at odds in consumer electronics.

Today, technology professionals face the challenge of maintaining precision and quality while minimizing waste and mitigating environmental impact as much as possible.

This need is not driven just from a manufacturing perspective. In addition to businesses having to adopt an environmental conscience in their production, consumers are also becoming increasingly mindful.

As a result, innovative approaches that fundamentally rethink traditional manufacturing processes are now at the forefront of production in the electronics space.

Michael Belhassen, 26, is a product design engineer at Apple, whose precision molding innovations demonstrate how sustainable manufacturing can enhance, rather than compromise, product performance. The techniques he has been involved in implementing are frequently adopted by the company’s competitors.

Belhassen has also been at the forefront of sustainable practices, which Apple takes seriously as an industry leader: “Our green approach, and every change or innovation we drive, whether it's acoustic. new enclosures, or any of the developments we have, more often than not, they pave the way for the next evolution in our competitors,” he says.

But what makes Belhassen's approach particularly compelling is how it emerged from both rigorous academic training and real-world application.

He says this was born from an early fascination with how things work: “Dissecting products, understanding their mechanics and looking at how everything fits together was something I was interested in from an early age,” he reveals. “It evolved into a drive to innovate in consumer electronics, which is what drives me today.”

He adds: “It is imperative that we not only maintain sustainability in production but look to improve as we continue to move forward. The reward being the consumer can have a better product with the satisfaction that it has been created from start to finish with the least amount of impact from an environmental perspective.”

Academic Foundation in Materials Innovation

Belhassen's passion for product engineering in particular was sparked early, when he was inspired by Apple CEO Steve Jobs and his philosophy of blending technology with design to create transformative products.

He remembers: "By age six or seven, I was captivated by consumer electronics—watching keynotes, diving into YouTube videos about new phones, and dreaming of working at a place like Apple."

A childhood visit to Apple's campus cemented his ambitions. Standing there, Belhassen told his father: "This is where Steve Jobs works, and I want to work here someday." That moment, and his father's belief that hard work could make it possible, set his trajectory.

But Belhassen’s exploration of sustainable design began during his academic work at Imperial College London. He graduated with First Class Honors in 2021: "During my master's at Imperial College, I wrote a paper on shape-memory materials for 3D-printed glasses, aiming to create customizable, durable eyewear,” he recalls.

“The paper explored how electrical currents could restore a material's shape, addressing both manufacturing and user comfort. This was the start of my exploration of the end-to-end journey of sustainability from the beginning of production to the end when the consumer handles a device."

This academic foundation in materials science would prove instrumental in shaping his later professional innovations.

Mechanical Engineering Excellence Through Three Core Passions

Belhassen's approach to sustainable manufacturing stems from three fundamental aspects of his mechanical engineering work: "First, I love the transition from concept to physical product,” he reveals.

“Taking an idea, like a new sensor or audio system, and turning it into a tangible device that millions use is magical.” And for Belhassen, this process is key in optimizing material usage and manufacturing efficiency.

His second passion builds on this foundation: "I enjoy the responsibility of owning critical components. That ownership drives me to push boundaries."

This ownership mentality naturally extends into working with others: "Working with cross-disciplinary experts is incredibly rewarding," he adds.

Belhassen has the opportunity to do this frequently, working with mechanical engineers and collaborating with material scientists,  automation specialists, and reliability engineers almost every day. He believes this creates a dynamic environment where diverse expertise converges.

Revolutionary Precision Manufacturing Breakthrough

These collaborative skills proved essential when tackling one of his most significant technical challenges. Traditional manufacturing approaches for small components generate substantial material waste.

However, Belhassen showcased his product engineering expertise when he developed a precision molding technology that addresses this fundamental inefficiency. The results exceeded expectations in both scale and impact: "By optimizing tooling, we reduced material waste equivalent to removing 2,000 cars' worth of emissions annually.” He states the result with modesty. But it was a significant achievement.

However, achieving this breakthrough required overcoming substantial technical hurdles: “The technical complexity proved significant. Belhassen adds.

"One challenge that ended up being quite rewarding was developing precision molding technology. Solving that felt like a victory, especially knowing it contributed to sustainability."

Comprehensive Problem-Solving Methodology

This precision molding success exemplifies Belhassen's broader problem-solving philosophy. His methodology balances technical precision with broader considerations: "When designing a component's electrical layout, I think about how it impacts user experience, manufacturing feasibility, and even sustainability,” he says.

Belhassen credits his “outside-the-box thinking” with enabling him to find creative solutions, such as his precision molding innovation.

What distinguishes Belhassen's approach is the relentless pursuit of solutions—a methodology that resonates strongly with colleagues who recognize his natural leadership abilities.

Jag Dhillon, a fellow Product Design Engineer, reflects on working with him: "Michael is incredibly well-mannered and kind. What stands out, though, is that he's a natural leader. Whether it's casually deciding where to eat or driving critical meetings at work, he steps up and takes initiative.”

Dhillon adds: "His confidence is natural; it's not something he has to force." You notice it the moment you meet him. Michael brings an extraordinary mix of technical expertise and visionary thinking. He refines what's already there and then pushes the boundaries of what's possible. Whether it's phones or any other future tech, his ideas are innovative, and he has the drive to execute them."

These problem-solving values translate directly into solving tangible user problems. Belhassen reveals: "Users may not see the engineering behind it, but they feel the difference when their phone lasts longer or performs reliably in demanding scenarios."

An example of this in action came in the form of the ultimate validation in measurable user impact with one area his work serves through iPhone use.

It was a complex application of user-centered principles involving audio technology, where Belhassen's expertise in acoustic systems truly shone.

He tackled an ambitious engineering challenge: "This was a three-year effort to integrate microphones capable of professional-grade audio recording into a device as compact as a phone," he explains.

"Navigating those discussions, while challenging, taught me to communicate technically and empathetically, which has made me a better engineer.”

It is something Belhassen is rightly proud of: "We enabled musicians and content creators to use their iPhones as professional tools, reducing the need for expensive equipment."

Success in complex projects, such as audio systems, requires sophisticated team coordination. Belhassen adds that collaboration drives his approach to complex challenges: "Convincing mechanical or software teams to align on a solution requires translating complex concepts into a shared vision," he explains.

Belhassen's technical foundation enables both credible leadership and seamless integration of diverse engineering requirements. This approach maintains a focus on user experience, and environmental responsibility remains equally prioritized.

Mentorship and Professional Development

Beyond leading projects, Belhassen invests significantly in developing the next generation of engineers.

At Apple, he is heavily involved in the Buddy Program, a formal mentorship initiative. It has given Belhassen the opportunity to work with three full-time employees and mentor around 30-40 interns over the past couple of years.

His mentoring philosophy reflects the same directness that characterizes his engineering approach: "Mentoring is a passion of mine because I believe in pushing others to reach their potential. I'm direct but empathetic, ensuring mentees get constructive feedback to grow quickly."

This commitment to knowledge sharing extends through his international experience and collaborative approach.

Harlan Dannenberg, Product Design Engineer at Apple, notes Belhassen’s valuable contributions: "I have been very grateful for the insights he has shared with me about how the team is working abroad, which helped me understand their perspectives on design and potential challenges they might pose to my work.

"Michael's open-mindedness and willingness to embrace new challenges also enables continuous innovation within his engineering role.

“His transparency in sharing both successes and challenges creates an environment where team members learn from each other's experiences.  It helps us to be much more cohesive.”

Beyond his primary role, Belhassen also actively participates in technology development: "I regularly participate in hackathons in San Francisco, which is a hub for tech innovation."

These events provide opportunities to contribute expertise and stay current with emerging trends: “In one hackathon, I mentored a team developing a wearable sensor, advising them on power efficiency and spatial optimisation to make their prototype more performant and compact. Judging these events lets me share my knowledge while staying connected to emerging technologies."

User-Centered Impact Philosophy

From precision molding to mentorship to hackathon participation, Belhassen's work directly addresses user needs: "I ensure that users get a reliable, high-performance device that enhances their daily lives without them noticing the complexity behind it. I’m proud that my contributions to enclosure and microphone systems mean users can drop their phone without losing functionality or record professional-grade audio on the go."

Colleagues who have observed his work over multiple years consistently note his forward-thinking approach to technology development.

Saad Haq, Senior Product Design Engineer, shares his perspective: "We've had lots of philosophical debates about how to move beyond screens and create more meaningful tech experiences.”

He adds that in engineering, people often rely too much on their expertise or ego, but Belhassen sets that aside: “He's excellent at identifying everyone's strengths and organizing the work so that each person contributes where they shine.

“I would say he's a visionary. He is continuously looking at how to refine what he’s working on and also thinking about what comes next."

This philosophical approach to technology development drives Belhassen's broader vision for the industry.

Taking Tech To The Next Level

Belhassen says he now has aspirations that extend beyond technical achievement to fundamental changes in human-device interaction: "I'd like to be remembered as someone who cared deeply about both the technology and the people behind it. For my colleagues, I hope they see me as a hardworking and empathetic leader who has helped them reach their full potential. And on a broader scale, I aspire to change how we interact with devices.”

Tomer Cohen who is a Senior Defence Industry Product Consultant, employed Belhassen as an intern in 2017 has no doubt he can achieve his goal. They worked together when Cohen was a co-founder of RideOn, a start-up that provided enhanced solutions for use in extreme sports.

He says Michael benefited RideOn immensely through his innovation, which expanded their product lines: “His honesty, which refined our pitches; his high work ethic, which kept momentum high; and his moral values, which created a positive team dynamic, all contributed to our success.

“Michael is already creating value through his work at Apple, driving growth in consumer electronics and maintaining the US's tech advantage.”

Cohen adds: “Societally, Michael's moral compass and supportive nature make him a positive influence; in tough times, he remains cool, observant, and realistic, offering guidance on global issues and serving as a role model for innovation with integrity. As a product engineer, Michael's skills will advance US technology, making him an invaluable addition to any company.”

This forward-thinking approach is just another illustration of how Belhassen’s vision extends to reshaping the role of technology in society itself.

His ultimate goal involves fundamentally changing how people interact with technology: "I aspire to transform the way we interact with our devices, designing systems that enhance human connection rather than diminish it,” Belhassen says.

“In today's world, technology often pulls us away from our loved ones, absorbed by screens and apps designed to capture our attention for profit.

“My goal is to create products that help us be more present, foster better relationships and become more productive. I aim to achieve this within the next 10-20 years, leveraging my position in consumer electronics to drive this change."

Belhassen demonstrates how product engineering expertise can address environmental challenges while enhancing user experiences. His work proves that the most impactful innovations emerge when technical excellence serves both human and ecological needs.