Sandwich Panel Composite Forms
Molds and forms built for laying up foam-core sandwich panels — the tooling that comes before the layup ever touches resin.
Mold & Plug
Machining & Precision Fabrication
CNC mill and router, lathe, surface grinder to half a thousandth, waterjet, laser, and sheet metal. Knowing what happens to a part on the machine makes me better at designing it.
Machining
Aluminum Up-Feed Saw
A rebuild of master machinist Andries Breedt's pneumatic up-feed saw for cutting aluminum to precise lengths.
Rebuild
Foam R&D Prototype
A quick prototype shaped in foam — the fast, cheap way to test a form before committing to tooling.
Prototyping
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Static Mixer
A mid-sized static mixer I designed for a silicone manufacturer so they could stop mixing by hand. I did the design and the laser etching; our in-house shop fabricated it.
Design + Etching
Crating & Shipping
Custom crates for moving oversized things across the country — framed, padded, and packed for flatbed and freight.
Logistics
Silicone Drill Fixture
A programmed fixture that holds a soft silicone sleeve to its exact shape so it can be drilled to a hard tolerance without distorting.
Fixture Design
Landing-Gear Fixture Plate
A ground pedestal-plate fixture that holds awkward landing-gear castings for machining — cheaper and lighter than a solid-block negative.
Workholding
Large Drive-In Fridge Build
A large drive-in fridge, framed and insulated from scratch for cold-chain storage on a working production floor.
Design + Build
Heavy Operations
Moving things that don't move easily: craning bioreactors onto flatbeds, threading fermentation tanks through doorways. You plan the lift, you don't muscle it.
Rigging
Laser Art & Signage
Laser-cut work for outside businesses and my own brands alike — etched wall art, restaurant and gallery signage, and branding for Space Campers and Whalebird, cut and etched start to finish.
Design + Laser
The Depalletizer
A depalletizer built from scratch to single-file cans onto the canning line in fifteen feet of space instead of the usual forty. Timed bursts of air popped the cans free from their nests, and a cheap drill turning an Acme screw drove the lift.
Design + Build
Counterweighted Lifting Tool
A counterweighted "rafter lifter" that lets one person raise heavy material up and into place safely.
Design + Build
Building Plug Stock
Building up MDF and foam stock into blanks ready to be CNC-cut into a plug — the prep work that makes the rest of the process go faster.
Mold & Plug
Space Campers Prototype Molds
Prototype molds built through several iterations for Space Campers composite parts, ahead of the final cap plug and tooling.
Mold & Plug
Space Campers Cap Plug
The plug was too big for the router, so we built it as a 3D puzzle out of MDF, skinned it, then hand-sanded for weeks until it was clean enough to pull a tool off of.
Mold & Plug
Vacuum Infusion
Resin pulled through dry fiber under vacuum for a clean, strong, repeatable part, with a foam core kitted in for stiffness without the weight.
Composites
MDF Plug Work
Plug and mold work cut from MDF on the CNC router — the shaping step that comes before a part ever sees resin, often kitting a large shape from smaller routed pieces.
Design + CNC
Microphone Housing
A machined mic housing in copper and black nickel for a sound engineer — I proposed fifteen-plus designs, machined them, and did all the laser etching myself.
Design + Machining
Folding Aerator Design
A folding aerator worked through from concept to a functioning mechanism.
Design
Boeing Brake-Sleeve Tool
A tool I led the design of for Boeing that pulls a 737 brake sleeve without damaging it — solving a problem their hydraulic tool couldn't. (Design and FEA shown.)
Design Lead
Interference-Fit Assembly Press
A press that interference-fits three over-molded pieces of a medical part together in one clean operation — the assembly step, not the molding.
Design + Build
3D-Printed Plugs
Small plugs and pattern pieces printed directly rather than machined, when the geometry favors it.
Prototyping
3D Printing
In-house 3D printing for rapid prototypes, custom fixtures, and one-off functional parts.
Capability
Production Aids
Small aids for a silicone production line — trimming flash, sampling parts, and checking wall thickness.
Process Engineering
The Heat Engine
An after-hours build: a heat engine I designed and machined to turn a temperature difference into motion, with a laser-cut turbine and a machined core.
Personal
Small Fridge Build
A smaller fridge build using the same cold-storage approach as the larger unit, scaled down for a tighter footprint.
Design + Build
Tasting Room Buildout
Facility build-out for a tasting room, from framing and utilities through finish work.
Facility Build-Out
Tesla Turbine
A bladeless Tesla turbine built from stacked acrylic discs — a personal build exploring boundary-layer flow.
Personal
Extrusion Drill Fixture
A simple fixture that locates an extrusion against a stop so the hole lands in the same place every time.
Fixture Design
Composite Panel Work
Side work for a local van-build company: laser-cut panels that puzzle together into finished composite parts.
Composites