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10 years of turning ideas into world class systems, from special mission aircraft to foiling race yachts.

Mechatronic Design on the World Stage

Liam Shanahan america's cup engineer for american magic

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USAF - Aircraft Systems Engineer<h3>At a Glance </h3><ul><li>Led systems engineering for outfitting, upgrading, and sustaining both manned (E‑11A) and unmanned (EQ‑4B Global Hawk) platforms with BACN payloads—serving as airborne, high-altitude data-link gateways facilitating voice, imagery, and tactical data relay.</li><li>Engineered integration of tactical data link systems (e.g., Link‑16, SADL, SATCOM, UHF/VHF radios) into BACN to enable real-time interoperability among heterogeneous air, ground, and coalition assets.</li><li>Coordinated modification testing, FAA/TAA airworthiness certification, and sustainment operations to ensure BACN-equipped Global Hawks and E‑11As maintained continuous beyond-line-of-sight (BLOS) communications capability in demanding theaters, including persistent 24/7 orbits.</li><li>Collaborated with industry partners on rapid fielding and modifications of this Joint Urgent Operational Need (JUON).<figure id="figure-46fom07rfimea81e2f" class=""><img id="46fom07rfimea81e2f" src="https://cdn.durable.co/blocks/37xwU5uLW2XeVQDfOudq0jdAr18JGXxY5E3GQ6sXS81hNmFSk6zQiwZTtn7nRMZN.png" alt="" title="" class="object-cover bg-gray-100 rounded-sm md:rounded-md lg:rounded-lg" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/37xwU5uLW2XeVQDfOudq0jdAr18JGXxY5E3GQ6sXS81hNmFSk6zQiwZTtn7nRMZN.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure> ________________________________________________________________ &nbsp; Battlefield Airborne Communications Node (BACN) Overview What is BACN? BACN is a high-altitude airborne gateway—deployed onboard both unmanned EQ‑4B Global Hawks and manned E‑11A aircraft—designed to act as a universal translator and relay between disparate tactical data and voice systems. It enables seamless, real-time communication across the battlespace, overcoming line-of-sight limitations, terrain, and incompatible systems.</li></ul>Core Capabilities &amp; Mission Impact<ul><li>Relay &amp; Translation: BACN bridges systems like Link‑16, SADL, UHF/VHF, SATCOM, and imagery links—allowing units with no direct compatibility to communicate and share situational awareness without hardware modifications.</li><li>High-Altitude Persistence: When mounted on Global Hawk UAVs, BACN operates from altitudes above 60,000 ft for endurance missions exceeding 30 hours, ensuring persistent comms coverage.</li><li>Terrain Mitigation: BACN overcomes communication challenges in mountainous or extended-range theaters, ensuring connectivity for air and surface forces and enhancing common operational pictures.</li><li>Recognition of Excellence: In 2010, BACN and its industry collaborators received the Network Centric Warfare Award for significantly advancing battlefield communications.</li></ul>Platforms &amp; Program Evolution<ul><li>EQ‑4B Global Hawk: Four unmanned Global Hawks retrofitted with BACN payloads sustain high-altitude data relay roles.</li><li>E‑11A (Modified Global 6000/BD‑700): A commercial business jet adapted as a BACN platform—dubbed “Wi‑Fi in the sky”—providing rapid deployment comms relay.</li><li>The USAF maintains a fleet comprising both platforms to ensure mission flexibility.<figure id="figure-52fovj54p4mea8a1sw"><img id="52fovj54p4mea8a1sw" src="https://cdn.durable.co/blocks/14uyRMn58KDgn0pCPFWIrKnoUXNJ9IR4fwlQRW9DUwewZCpoVbi28n6qQ4UOUJiv.jpg" alt="" title="" class="object-cover bg-gray-100 rounded-sm md:rounded-md lg:rounded-lg" style="aspect-ratio: 16/9; object-position: undefined undefined;" data-corners="default" data-aspect="16:9" data-caption="Link 16 tactical data link" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/14uyRMn58KDgn0pCPFWIrKnoUXNJ9IR4fwlQRW9DUwewZCpoVbi28n6qQ4UOUJiv.jpg" data-mce-style="aspect-ratio: 16/9; object-position: undefined undefined;"><figcaption class="body-normal text-gray-500 mt-2">Link 16 tactical data link</figcaption></figure></li></ul>

USAF Battlefield Airborne Communication Node (BACN)

Stars &amp; Stripes – Simulator Engineer <h3>At a Glance </h3><ul><li>Developed a custom simulator for the AC75 foiling monohull, enabling sailor training, control system testing, and CFD model integration.</li><li>Integrated Gomboc physics engine to model aero-hydro interactions unique to foiling yachts. </li><li>Collaborated with elite engineers and sailors to validate system architecture and control logic. </li><li>Prototyped concepts for a 6-axis motion platform simulator inspired by Team New Zealand’s winning setup. &nbsp;<figure id="figure-vxu2s28csmmea59h1y"><img id="vxu2s28csmmea59h1y" src="https://cdn.durable.co/blocks/6zAHs62EpNDBXsvxlthJtfEgZ0RixIEcZeInU4syJf2BmVlRtkA39uX69egOCmhx.jpg" alt="" title="" class="object-cover bg-gray-100 rounded-sm md:rounded-md lg:rounded-lg" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/6zAHs62EpNDBXsvxlthJtfEgZ0RixIEcZeInU4syJf2BmVlRtkA39uX69egOCmhx.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure><h3>My Role</h3>___________________________________________________________</li></ul>In January 2019, I joined Stars &amp; Stripes, a new challenger aiming for the 36th America’s Cup. This was a dream role—having followed the revolutionary foiling catamarans of AC34 and AC35 since high school, I now had the chance to help tackle an even more radical concept: the AC75 foiling monohull.The AC75 was unlike anything before—75 feet long, monohull above the waterline, but supported by two giant actuating foil arms beneath. At the time, many questioned whether it was even possible to sail. Our small team of under ten people, led by match-racing world champion Taylor Canfield and marketing innovator Mike Buckley, set out to prove it could be done.I was one of five engineers on the project, working alongside:<ul><li>Two founders of Vakaros (tactical sailing electronics) developing the onboard control systems.</li><li>JB Braun, team CTO and Director of Desing at North Sails</li><li>Bryan Baker, aerodynamics specialist with years of cup experienve</li><li>Myself — responsible for building the team’s simulator for hardware-in-the-loop testing and sailor training. &nbsp; Simulator Development</li></ul>The simulator was the technical heart of my role and a cornerstone of our campaign’s engineering and training strategy. Its purpose was to:<ul><li>Allow sailors to begin training on a boat that didn’t yet exist.</li><li>Give designers a way to test new CFD-based aero and hydro surfaces in a dynamic environment.</li><li>Enable control engineers to refine the AC75’s complex onboard systems before hardware was built.</li><li>Serve as a portable showcase to attract sponsors and donors. &nbsp; Research &amp; Architecture</li></ul>Early in development, the team secured the opportunity to purchase limited intellectual property from Emirates Team New Zealand, the Cup defenders. This included a visit to Auckland to study their systems firsthand.We got to look under the hood of their motion platform simulator, originally developed for their AC35-winning foiling catamaran and now being adapted for the new AC75. At its core was Gomboc — a tool developed by team NZ but was now an off-the-shelf simulation software package. Gombocs greatest strength was a robust physics engine designed specifically for foiling yacht performance modeling. Gomboc excels at computing the combined aero-hydro forces across the air–water interface, which is essential for accurately simulating foiling yachts where both wind and water dynamics are tightly coupled.<figure id="figure-poziga7o1gmea62zc0"><img id="poziga7o1gmea62zc0" src="https://cdn.durable.co/blocks/295eZVOiUS5AMkKHOL0rTXyVn10BDICHR0RtKBNPkWgMwCYvjdOkM3CPDxjS683j.png" alt="" title="" class="object-cover bg-gray-100 rounded-sm md:rounded-md lg:rounded-lg" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/295eZVOiUS5AMkKHOL0rTXyVn10BDICHR0RtKBNPkWgMwCYvjdOkM3CPDxjS683j.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>Armed with my new understanding of Team NZs highly refined simulation system, I was able to begin work on our own. From this visit, I was able to reverse-engineer the simulator’s system We decided to use the same Gomboc physics engine and create a small, standalone simulator to begin with. &nbsp;This would allow Bryan to input and test new aero and hydro CFD models and surfaces, &nbsp;the Vakaros boys to tweak and test system controls and dynamics, the sailors to train and understand the dynamics of sailing a boat that does not yet exist, and we would also be able to tranport this simulator to fundraising events around the country to allow people to "sail an AC75", and drum up excitement for our campaign.&nbsp; Building the Stars &amp; Stripes Simulator Armed with that knowledge, I began building a standalone Stars &amp; Stripes simulator using the same Gomboc engine. This initial version was designed to run without a motion platform, allowing us to get sailors, designers, and controls engineers working immediately.Key features included:<ul><li>CFD model integration: Bryan Baker could rapidly load updated aero/hydro models from ongoing design work.</li><li>Controls testing: The Vakaros engineers could implement and test their control logic for the foils, rudders, and sail trim systems in a realistic physics environment.</li><li>Sailor training: Sailors could begin learning the handling characteristics and balance of an AC75 well before the boat was physically built.</li><li>Portable engagement: The simulator could be transported to events and set up within minutes. &nbsp;<figure id="figure-zysqgha5ramea6be94"><img id="zysqgha5ramea6be94" src="https://cdn.durable.co/blocks/1bbBsIN9dSfuWTlT8yZnDSJ89D4Of8KutYW0wW24yxCqFZDuS4BbIo7QbcrYiFVs.jpg" alt="" title="" class="object-cover bg-gray-100 rounded-sm md:rounded-md lg:rounded-lg" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/1bbBsIN9dSfuWTlT8yZnDSJ89D4Of8KutYW0wW24yxCqFZDuS4BbIo7QbcrYiFVs.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure> From Desktop Rig to Immersive Experience The earliest build used a Logitech video-game steering wheel and pedal set hooked to a standard monitor. While functional, it was far from realistic. I redesigned the interface to include:</li><li>A custom-built carbon fiber steering wheel modeled after the actual AC75 helm, with integrated thumb controls for trimming, foils, and flight control.</li><li>Foot controls for secondary inputs, matching real-world ergonomics.</li><li>VR headset integration for full 360° situational awareness in the virtual cockpit.</li><li>This upgrade transformed the simulator from a basic software testbed into a realistic training and engagement tool.</li></ul>&nbsp; On the Road: Fundraising &amp; Public Engagement Still being an early stage team, fundraising was still a high priority at this stage. Therefore, Mike and Taylor were planning to throw a massive fundraising event at an estate in Bel Air, Los Angeles. Recognizing its value beyond engineering, We decided we wanted to showcase the simulator at the event to get people excited about the team. I created a timed racecourse in the simulator and wrote a real-time leaderboard system. Guests could attempt to beat the team driver, Taylor Canfield’s lap time, with results instantly displayed on a secondary screen.This approach gamified the experience, giving high-profile attendees a taste of the AC75 challenge while reinforcing the brand’s energy and innovation.<figure id="figure-rwkuxzektmmea6r840"><img id="rwkuxzektmmea6r840" src="https://cdn.durable.co/blocks/33MVK85PsXFV2MIB1PTqanGzEMAXgVpVHNB2ZGQeNKAPfz1ILLYTRXjira56vQbP.jpg" alt="" title="" class="object-cover bg-gray-100 rounded-sm md:rounded-md lg:rounded-lg" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/33MVK85PsXFV2MIB1PTqanGzEMAXgVpVHNB2ZGQeNKAPfz1ILLYTRXjira56vQbP.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>&nbsp; Planned Expansion The next development phase was a full 6-axis motion platform simulator, mirroring Team New Zealand’s system. This would have enabled hardware in the loop testing, as well as allowing the entire crew to train together with realistic motion feedback. Unfortunately, funding constraints ultimately cut this project short as our America's Cup dreams were dashed.&nbsp; Takeaways The simulator project demanded a fusion of systems engineering, physics-based modeling, custom hardware design, and user experience thinking. In less than a year, I took it from concept to an operational platform that served as both a serious engineering tool and a compelling marketing asset—all within the constraints of a small, fast-moving startup team.<figure id="figure-9yifqxlyoamea761hb"><img id="9yifqxlyoamea761hb" src="https://cdn.durable.co/blocks/35TxPABDqvJ0e4mwvUuZL4NJPadneOZVqg9AluU9zEvTWaqQ3vCththMKTawTOOi.jpg" alt="" title="" class="object-cover bg-gray-100 rounded-sm md:rounded-md lg:rounded-lg" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionX="undefined" data-positionY="undefined" data-fullWidth="false"/></figure>

Stars & Stripes AC36

North Sails – 3Di Windsurf Adjustable Molding System<h3> At a Glance</h3><ul><li>Designed and built a discretely adjustable 3D mold for composite sail manufacturing with 58 individually controllable actuators.</li><li>Developed a precision surface-shaping system with accuracy to ±0.5 cm, enabling molding of any sail profile from a single tool.</li><li>Engineered an integrated heating and vacuum curing system to cure sails at 100 °C in under 7 minutes.</li><li>Created a Linux-based graphical user interface (GUI) for simple operator control of actuators and curing process.</li><li>Increased production capacity to 40+ sails per day, enabling scalable manufacturing of 3Di windsurf and dinghy sails.</li><li>Delivered a cost-efficient, reconfigurable mold that eliminated the need for costly, single-purpose composite molds and enables brand new sail shapes to be created by simply uploading a new configuration.<figure id="figure-vp2y8dj6g5me92x6gv" class=""><iframe id="vp2y8dj6g5me92x6gv" src="https://www.youtube.com/embed/b7lSonPWgzQ" class="w-full bg-gray-100 rounded-sm md:rounded-md lg:rounded-lg" style="aspect-ratio: 16/9;" allowfullscreen="" data-url="https://youtu.be/b7lSonPWgzQ" data-corners="default" data-fullwidth="false" data-mce-src="https://www.youtube.com/embed/b7lSonPWgzQ" data-mce-style="aspect-ratio: 16/9;"></iframe>________________________________________________________</figure></li></ul><h3>My Role</h3> Project Context North Sails is a global leader in high-performance sail manufacturing and the inventor of 3Di composite sail technology—a process that molds sails in three dimensions using precision-laid composite fibers and advanced resin. This technology produces sails that are lighter, stronger, and more durable than traditional Dacron or Mylar sails, and it dominates the professional racing scene from superyachts to TP-52s.However, 3Di had been largely out of reach for smaller classes like windsurfers, dinghies, and kites. The main barrier was manufacturing economics: existing 3Di molds were enormous, single-purpose, and optimized for large yacht sails. Producing small sails on this equipment was slow, costly, and impractical.The Challenge I was brought in to help adapt 3Di technology to small-format sails by developing an adjustable molding system that could replicate the precise curvature of any sail profile. The system needed:<ul><li>Universal compatibility with any windsurf or dinghy sail shape.</li><li>Precision surface control within ±0.5 cm over a 25 ft span.</li><li>Fast reconfiguration for rapid design iteration.</li><li>Integrated curing capability for high-throughput production.</li></ul><figure id="figure-4xdi2324lpme932l27"><img id="4xdi2324lpme932l27" src="https://cdn.durable.co/blocks/6hU6zVZGTTkdVFt4QaVTRzYtMwlD98eNlnZB81ZOzfk2jFXUdK0Mcvd0siDHfk4Q.jpg" alt="" title="" class="object-cover bg-gray-100 rounded-sm md:rounded-md lg:rounded-lg" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/6hU6zVZGTTkdVFt4QaVTRzYtMwlD98eNlnZB81ZOzfk2jFXUdK0Mcvd0siDHfk4Q.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure> Engineering the Solution<ul><li>Adjustable Mold Design: We built a 10 ft × 25 ft molding table with 58 independently controlled actuators, each able to position the mold surface to match any CAD-defined sail shape.</li><li>Integrated Heating &amp; Vacuum Curing: Designed a dual-silicone blanket and heat-blanket system to cure sails in position at 100 °C under vacuum. This reduced cure times to 7 minutes and allowed two people to complete a sail in under 30 minutes.</li><li>User-Friendly Control System: Created a Linux-based controller with an easy to use GUI so operators could load sail designs, adjust actuator positions, and control heating/vacuum processes without deep technical training.<figure id="figure-5qu522ryzame93qfhf"><img id="5qu522ryzame93qfhf" src="https://cdn.durable.co/blocks/15ANRzb3jyksO79ITqV999uMOGkT9ISmwyrOA1qzdKyW0VBUrFXJpSPt2XPgxdIZ.png" alt="" title="" class="object-cover bg-gray-100 rounded-sm md:rounded-md lg:rounded-lg" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/15ANRzb3jyksO79ITqV999uMOGkT9ISmwyrOA1qzdKyW0VBUrFXJpSPt2XPgxdIZ.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure></li><li>Rapid Iteration &amp; Scalability: Enabled testing of dozens of sail profiles within the first month, paving the way for a production capacity of 40+ sails/day.</li></ul><figure id="figure-yiga235kwpme933irx"><img id="yiga235kwpme933irx" src="https://cdn.durable.co/blocks/32VcUrvVD5hLgyQV0jjgmTMrr9kCn2lSi0pp65rRn5RLJmE3N0T9yUwF0vuMCkjy.jpg" alt="" title="" class="object-cover bg-gray-100 rounded-sm md:rounded-md lg:rounded-lg" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/32VcUrvVD5hLgyQV0jjgmTMrr9kCn2lSi0pp65rRn5RLJmE3N0T9yUwF0vuMCkjy.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>Impact This system unlocked affordable 3Di technology for windsurfers and other small sails, eliminating the need for multiple fixed molds or taking up space on the massive superyacht mold.&nbsp;It also allows for new sail models to be tested and brought to production quickly.&nbsp; To generate a brand new sail shape, you need only upload the new configuration file and watch the mold take shape.&nbsp; The project combined mechanical design, precision mechatronics, control systems, and manufacturing process engineering—and transformed an elite technology into a scalable, mass-market product.This system has worked reliably for 5 years now pumping out windsurf sails around the clock. And fortunately, I've 'barely' recieved 2am calls from Sri Lanka asking for debugging help when the machine malfunctions.&nbsp;<figure id="figure-w0w195ajxome937aci"><img id="w0w195ajxome937aci" src="https://cdn.durable.co/blocks/1agSlci2mybwXASRb8kpTlgXQ5CvxHmVZZZNZ2lKxBf7CsJ6XsayNpbr9xWMswhd.png" alt="" title="" class="object-cover bg-gray-100 rounded-sm md:rounded-md lg:rounded-lg" style="aspect-ratio: 16/9; object-position: center center;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/1agSlci2mybwXASRb8kpTlgXQ5CvxHmVZZZNZ2lKxBf7CsJ6XsayNpbr9xWMswhd.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>

North Windsurf

Quote/testimonial

“He understood the science of sailing, but he also understood the art of it, which is baffling to a lot of scientists.”

“Few sporting events capture a sailor’s imagination more than the America’s Cup, and Liam Shanahan ’18 counts himself among the enchanted.”

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