Holding a CNC-cut hexagonal-pattern intake grille up against the orange Can-Am Maverick X3's engine bay.

[WORK INDEX]

PROJECTS

FIFTEEN BUILDS · CLIENT AND SELF-DIRECTED

Client commissions, R&D studies and things I built because the problem was interesting. Everything here was designed, made and photographed in-house.

[MORGAN HILL · CA]

[INDEX]

All of it.

01 AiRACER-01 Hover Platform MECHANICAL DESIGN 02 Can-Am Maverick X3 Intake Relocation CAD 03 Karbonic-600X Carbon Quad Frame STRUCTURAL DESIGN 04 RC Ford Raptor Monster Truck Rebuild CHASSIS 05 Shadowtrooper Helmet, 1:1 1:1 SCALE 06 R&D CAD Studies SOLIDWORKS 07 AX-12A Servo Hexapod KINEMATICS 08 CNC Routing & Machining CAM 09 Laser Cutting & Engraving LASER 10 Flight Controller Firmware & Electronics SCHEMATIC 11 Micro-Precision Fixtures PRECISION 12 AT-ST Walker Model MODEL MAKING 13 Bill Jacobson Trucking Peterbilt COMMISSION 14 Additive Manufacturing FDM 15 Custom Blade Prototypes ERGONOMICS

[01]

MECHANICAL DESIGNDUCTED PROPULSIONFLIGHT CONTROL INTEGRATIONADDITIVE MANUFACTURE

AiRACER-01 Hover Platform

A two-channel hovering race platform with altitude hold. The airframe, the ducts and the hub are mine; the flight-control stack runs dRehmFlight, developed by Nicholas Rhem. Designed in SolidWorks, rendered in Visualize for proportion checks, then printed, flown, broken and revised.

Close view of the orange quad-ducted hover platform's shrouded propeller and orange composite frame on the shop floor. — LEADDucted for a reason — bare props don't survive a Morgan Hill garage.

AiRACER-01, exploded. Drag to orbit — open a callout for the spec.

Full view of the orange quad-ducted hovering platform on the shop floor, four propeller shrouds and the central flight-control pod. — 01Height-locked, two-channel, and it actually flies. That's the hard part.

Custom FPV flight controller transmitter with an OLED telemetry screen, sitting on a wood workbench. — 02The stick feel matters more than the spec sheet.

03Branding you only see once the shroud comes off.

[02]

CADCNC MACHININGDFMINSTALLED ON VEHICLE

Can-Am Maverick X3 Intake Relocation

The stock Maverick X3 pulls intake air from directly behind the driver's head, which is loud and hot. I modelled and CNC-machined a relocation that moves the intake to the rear of the car, with a hex-pattern grille that keeps debris out without choking flow.

Close detail of the laser-cut honeycomb intake grille panel, edges still sharp off the cutter. — 01Every hex cell is doing airflow math whether you like it or not.

Can-Am Maverick X3 dash and door panel fitted with the relocated hex-pattern intake grille. — 02Fits like it came that way from the factory. It didn't.

[03]

STRUCTURAL DESIGNCOMPOSITERENDER

Karbonic-600X Carbon Quad Frame

A carbon-fibre X-frame quad platform. Structural layout driven by where the loads actually go, not by what is easy to cut.

CAD render of the Karbonic-600X carbon-fiber X-frame quadcopter, dramatic rim light across the arms.

LEAD Carbon fiber X-frame, cut for weight everywhere it doesn't matter.

Karbonic-600X quad frame render from a low front angle, showing the arm taper and motor mounts. — 01Every arm tapers by the same amount. That's not an accident.

[04]

CHASSISPACKAGINGELECTRONICS

RC Ford Raptor Monster Truck Rebuild

Stock Ford Raptor body over a chassis that is entirely rebuilt underneath — suspension geometry, drivetrain packaging, and the electronics tray.

RC Ford Raptor monster truck mid-rebuild, carbon fiber chassis plates exposed under the rear bed and tires stacked beside it. — LEADHalf torn down, half built back up — that's most of my weekends.

Front three-quarter view of the blue Ford Raptor RC body over its rebuilt chassis, aluminum shock towers and carbon fiber links visible. — 01Stock body. Everything underneath it is mine.

RC Raptor rear suspension and carbon fiber chassis rails, mid-rebuild under garage light. — 02Garage light is never the light you want, but it's the light you have.

[05]

1:1 SCALESEAM PLANNINGADDITIVE

Shadowtrooper Helmet, 1:1

Full-scale helmet, printed in sections, seam-planned in CAD so the joints fall where the geometry hides them. Client handled paint and finishing.

1:1-scale Shadowtrooper-style helmet in a dark satin finish, printed in one piece. — LEADBench-scale printer, full-scale helmet. Patience did the rest.

[06]

SOLIDWORKSSURFACINGVISUALIZE

R&D CAD Studies

Ongoing R&D. Gearbox housings, turbine stacks, gripper mechanisms — studies that exist to keep the modelling sharp and to prove a surfacing approach before a client job needs it.

CAD render of a red electric ducted fan rotor and housing assembly on a studio background. — LEADRed because it's the part that spins fastest.

CAD render of a robotic gripper mechanism mid-trial, light neutral finish. — 01Gripper revision four. It finally holds without crushing.

CAD render of a red head/rotor assembly component on a studio background. — 02Every assembly gets its own render before it gets cut.

CAD render of an aluminum gearbox housing on a dark gradient studio background. — 03The housing is half the design. Nobody notices until it leaks.

[NEXT]

Your project is the next index number.

Every job is quoted case by case — the technology, the approach and the end result decide the number. Tell me what you are trying to build and I will tell you straight whether I am the right shop for it.

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