Friction stir welding · with TWI
Stationary-shoulder FSW tooling
Led concept-to-final design with full FEM and thermal-management analysis in ABAQUS. Resulted in granted patent WO2025045755A1.
Portfolio
A selected record of work across superhard materials, space optics, ultraprecision engineering, structural design and engineering automation - spanning industry, research and collaboration. Most carry confidentiality terms, so detail is kept general.
Element Six
FEA, thermal simulation and characterisation of CVD diamond, PCD and pcBN, from concept to patent.
Friction stir welding · with TWI
Led concept-to-final design with full FEM and thermal-management analysis in ABAQUS. Resulted in granted patent WO2025045755A1.
Welding · with TWI, Resurgam & Saipem
ABAQUS Coupled Temperature-Displacement (transient) and Coupled Eulerian-Lagrangian models of the weld, validated against SEM/EDS nanostructure analysis of pcBN tool wear. Resulted in granted patent GB2631835A.
Aerospace · with Rolls-Royce
Structural stress analysis of PCD tool assemblies in ABAQUS, with design and prototype work in SolidWorks.
Optics · high-power laser
Full FEM of Gaussian laser-beam heat flux and thermal management of the CVD diamond window, in ABAQUS - optimising the mount for continuous high-power operation.
Materials · oil & gas
Qualitative and quantitative characterisation of new HPHT oil-and-gas PCD cutters and CVD material, including residual-stress measurement with numerical and experimental verification.
MDA Space
Optical design, test and verification across four missions, using Zemax and Imatest.
SIRC
Testing, evaluation and verification of the infrared camera, with numerical and resolution simulation in Zemax and Imatest, plus infrared lens design and space-grade material investigation.
FLARE
Laser-beam alignment and measurement, with lens design and calculation in Zemax and ImageJ.
Proba3
Neutral Density Filter modelling, plus engineering-model test and verification of the laser-fibre coupling - combining lab testing with Zemax simulation, laser focusing and spot calculation.
Astroscale
Design and development of a space infrared camera for spacecraft docking, including IR lens design and tolerancing in Zemax.
Qualification
Investigation and verification of commercial-off-the-shelf (COTS) optical products against space-grade material requirements.
PhD · Brunel University London
Smart tooling, compliant mechanisms and machine dynamics for freeform optics.
Patent GB201914672D0 · with JGJHVM Ltd
Invention and design of a compliant-mechanism chuck for clamping contact-lens mould inserts in diamond turning - FEA, CFD, experimental design and scientific data analysis. Held runout to a 16 nm standard deviation and a 4 nm Ra finish.
Precision machines
Design of a diamond-turning-machine hydrostatic bearing in metal matrix composite (MMC) material - CAD, FEA, multi-body dynamics and vibration analysis, validated experimentally.
Algorithms
A dynamics-oriented toolpath-generation method for optical freeform surfaces - programming, multi-body dynamics, experimental design and data analysis.
Manufacturing technology
Design and development of ultraprecision tooling and the associated machining technology for contact lenses - integrating CAD/CAM/CAE, fluid dynamics, FEA and machine kinematics.
Cross-cutting capability
Parametric automation, algorithms and data methods that cut repetitive engineering work.
Automation · Cameron (Schlumberger)
Replaced a manual multi-part modelling process with parametric modelling driven by programming - running flanges and fittings as features through a best-practice process to cut design time.
Automation · Cameron (Schlumberger)
A parametric, programmed tool that selects the right lifting lug for skid-mounted oil & gas products by capacity - CAD, FEA and data analysis - removing a slow, error-prone manual step.
Algorithms · research
Algorithmic toolpath generation for ultraprecision machining - programming, API and data-engineering work translating machine dynamics into a usable path.
Ove Arup & William Hare
Parametric structural modelling and FEA on landmark infrastructure.
Landmark towers & infrastructure
Parametric engineering design and modelling, with CAD, FEA and BIM, on complex projects including the Leadenhall Tower, ADIC HQ Tower, Abu Dhabi International Airport, Walbrook, Greenwich Peninsula and Quadrant 3.
Academic & competition projects
University and competition projects that built the hands-on base.
Academic · design
Design and development of an industrial micro-EDM electrode holder - product design, product-lifecycle management, CAD, FEA and data analysis.
Competition · with Shell
On the design team for an electric car to cut London emissions: designed and developed a light composite structural frame and chassis, using FEA and CFD.
Competition · with Shell
Aerodynamic and Formula-One-style surface design for the Shell Eco Marathon car - CAD, CAM, CFD and data analysis, using SolidWorks and Alias for technical surface modelling.
Academic · CFD
CFD-based design of a high-speed, air-driven robotic automotive paint-spray system - computational engineering, CAD, CFD and data analysis.
Tell me what you are working on and I will come back with how I can help.