Projects

As Work Package Manager for the pitching hub on Proteus—a global leader in tidal turbine systems with arguably the most experienced and accomplished team of tidal engineers in the world—I was responsible for integrating the mechanical and electrical equipment within the hub. The turbine is currently in operation in Japan.

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In November 2019 I was deployed with the Bloodhound team to the Hakskeen Pan in South Africa for 6 weeks and successfully completed high speed testing, reaching 628mph. As lead designer on over 50 internal assemblies, including the parachute system which I was personally responsible for packing and checking before each high speed run.

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Bloodhound SSC had two propulsion systems - rocket and Jet. For the rocket system I designed the tank, tank cradle and delivery lines. All materials had to be HTP compatible. The tank frame (pictured) required high strength, low weight and a delicate touch when clamping the tank to comply with the G loading constraints. The end design was a bespoke CNC’d 7075 T6 aluminium frame with specialist viton rubber bushes. The system was successfully tested in the test cell.

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PICTURE CROSS is a classic picture logic puzzle app for smartphones enjoyed by millions worldwide. I was instructed to create a real life, wall-mounted version of this digital app in the style of a vintage board game to use in a video guide which explains the basic techniques and walks you through solving a puzzle.​

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​A renowned British manufacturer, known for designing and hand-building premium compact folding bicycles, commissioned me to design a bespoke electronics housing for a new titanium-framed development bike. The housing was engineered to securely mount data-logging equipment, enabling real-time measurement of frame stresses during use in real-world riding conditions.

This project involved producing a functional end-use component for an automotive industry client, designed to securely mount test equipment while meeting demanding mechanical performance requirements. By using a high-quality micro carbon fibre-filled nylon filament with added continuous fibre in-lay, the final part achieved strength comparable to 6061 aluminium at a fraction of the weight and cost of an equivalent CNC-machined component.

​Another project for Proteus - global leader in tidal turbine systems - saw me designing, manufacturing and building three 1/80th scale models of the AR3000 turbine for the renewable energy exhibition in Milford Haven. I also designed a fourth model with display case which is used for conferences and exhibitions around the UK and France. The turbine’s hub and yaw rotates for a more tactile experience.

​Proteus wanted to incorporate an innovative individual blade pitching system to maximise turbine efficiency. For this they needed a strain gauge system within the blades to monitor real time operational loads. I identified a suitable optical strain gauge system. For the readings to be accurate, precise and consistent placement and bonding of the strain gauges across the 3 blade internals was critical. I designed and manufactured a custom jig (pictured) that allowed precise fitment of the gauges within the cramped and difficult internals of the blade roots.

This project involved the design and CNC manufacture of a bespoke bed system for the rear of a 1978 Volkswagen campervan. The system was developed to maximise space, improve comfort, and remain sympathetic to the original character of the vehicle. From concept development and CAD modelling through to CNC machining and installation, the final design delivered a practical, robust solution tailored to life on the road.

Embers Sauna, an independent, family-owned business offering high-quality, eco-friendly, wood-fired barrel sauna experiences, commissioned me to design and build bespoke wooden steps for their saunas. The steps were created to allow comfortable movement in and out of the sauna, provide a smooth yet non-slip surface, and remain true to the overall look and feel of the sauna.

I am currently working on various unique development projects for Think Drinks, a leading supplier of specialized, high-quality, pre-mixed cocktail bases and syrups to the UK hospitality industry. Constantly pushing the bar, we are working together to create new solutions to pouring systems and improving the whole bartender experience when delivering premium cocktails.

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I work with a world leader in autonomous vehicle systems and control, designing and manufacturing everything from bespoke electronics and sensor housings to electric steering and electric braking conversions and bespoke bracketry. Much of the work is retrofitting standard vehicles therefore integrating the specialist autonomous equipment involves innovative space saving designs to achieve the final solution.

For a client in the London hospitality sector, I designed, built, and installed a series of elegant bespoke dining pods. The pods were a modular design, allowing for easy transport to site and efficient on-location assembly, via a lift. Building on this work, I later developed a smaller, eco-friendly version using recycled materials in place of wood to reduce maintenance requirements, while maintaining both functionality and visual appeal.

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I worked with a client who specialises in autonomous heavy-lift un-crewed aerial vehicles (UAVs) which provide logistic, resupply and surveillance solutions within harsh environments. I was involved in its prototype which was carefully designed to carry up to 135kg of cargo over a maximum 400km.

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Ruggeddub is the result of a little book of ideas founded on years of experience in and around VW vans. Reinventing the big and the small things just to make them stronger, last longer and hopefully look a little bit better along the way. 

Designer and manufacturer of the Ruggeddub low profile, heavy duty VW Transporter roof bars.

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