Beginning behind manual knee mills and wire EDMs shaped my entire design philosophy. Knowing how chips form and cutters deflect ensures every CAD model respects physical tooling capabilities long before releasing drawings.
Over the last decade across robotics and aerospace hardware programs, that tactile foundation evolved into managing complex sub-millimeter kinematic stacks, thermal dissipation enclosures, and complete supplier qualification pipelines.
First-principles engineering process
Analytical modeling
FEA and tolerance stack
Functional prototyping
Environmental qualification
Establishing free-body diagrams, thermal resistance networks, and parametric multi-body kinematics before opening CAD. Solid mechanics govern initial volume allocation.
Subjecting preliminary geometry to non-linear stress simulation and statistical RSS tolerance loops to pinpoint deformation and binding risks early.
Machining critical interfaces in-house using rapid billet setups and direct 3D printed sacrificial cores to verify ergonomic and assembly kinematics.
Subjecting pilot production units to shock, cyclic thermal chambers, and strain-gauge telemetry to confirm survival against rigorous field specifications.
Julian delivers production-ready assemblies that assemble flawlessly on the first pilot run without costly tooling revisions or hand-fitting shims.
Marcus Vance, Hardware VP at Vector Robotics
Currently evaluating staff mechanical roles, critical sub-assembly contract retainers, and technical leadership opportunities for complex physical products.