Banner

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

Logo showcase

Recent blog posts

Featured Projects

Real-Time Racing Data, Right Where You’re Looking.start clock, time-to-burn, laylines, and wind shifts, the tactical data you need, at the instant you need it.<figure id="figure-g7qhwqsb6fmec0e1zv"><img id="g7qhwqsb6fmec0e1zv" src="https://cdn.durable.co/blocks/1bKFS7J0SR7Syt5MzhWTlZdYZNqh51Oqk8VqAFG0F9W3fbZeqs9Tycq6mdJH2yF0.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/1bKFS7J0SR7Syt5MzhWTlZdYZNqh51Oqk8VqAFG0F9W3fbZeqs9Tycq6mdJH2yF0.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>_____________________________________________________________<h3>SailView</h3>This project is still in its early stages, but I’ll be share my progress here and on the SailView website.The idea is this: in the next year or so, AR glasses like the Meta Orion will hit the market, and I believe people will begin relying more on their glasses to perform tasks they used to do on their smartphones. I want to start exploring AR glasses while building something useful.SailView is an app that runs on your phone and eventually Garmin devices to perform tactical sailing calculations and display them directly in your field of view.It’s designed for formula kite racers, dinghy sailors, and small, fast, wet, unstable craft where mounting a tactical computer on deck is impractical. These sailors still need the same tactical insights as larger boats—but can’t afford to look down at a watch or cockpit display. With SailView, you keep your eyes up and your mind on the race.This isn’t just GPS and compass data—it’s real-time tactical decision-making for the start line, wind shifts, laylines, and every critical point on the course.______________________________________________________________Phase 1 (Complete): App + AR Glasses Interface I started with a pair of off-the-shelf sports AR glasses designed for cyclists who want real-time speed, elevation, and heart rate without taking their eye off the road. They include a developer SDK, making it possible to adapt them for other sports like paragliding—and now, sailing.I built a cross-platform Flutter app for Android and iOS with the core UI layout and a working data link to the glasses, displaying test data.________________________________________________________________Phase 2 (Complete): GPS Data in the Glasses The app is built around “display modes”—modular tactical data views that I can easily expand and add to over time.The first proof-of-concept was 'Boat Speed Mode', displaying live GPS speed directly in view. This confirmed my data flow pipeline, helped me design the software architecture, and set up the visual asset system for easy future mode additions.Next step: I still have some sensor fusion work to combine GPS, compass, and IMU for higher-resolution yacht state awareness.<figure id="figure-s2z3mzifkamec0ffbh"><img id="s2z3mzifkamec0ffbh" src="https://cdn.durable.co/blocks/32H0xRBLoB03jQOu6qBKpE1FNTxIeqyQleunAAW7ZFLFMbscqXWSN0R5BEoL1mE1.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/32H0xRBLoB03jQOu6qBKpE1FNTxIeqyQleunAAW7ZFLFMbscqXWSN0R5BEoL1mE1.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>______________________________________________________________Phase 3 (Complete): Race Start ModeFor singlehanded sailors, keeping your head out of the boat during the prestart is critical. I wanted a way to subconsciously keep track of the start clock without looking down.So I built a set of custom graphics and animations that flash in your peripheral vision at key intervals (2:00, 1:00, 30s, 20s, 10s, 8, 6, 4, 2, GO).&nbsp; &nbsp;This allows you to keep your eyes and mind on pre-start tactics while your subconcious mind and peripheral vision, keep you informed on where you are in the start sequence.After GO, the app automatically switches to Tactical Mode.______________________________________________________________Phase 4 (In Progress): Tactical Mode This is the most challenging—and the most exciting—part yet.Most tactical tools require constant pings, calibrations, and manual input—often before every race. If the wind shifts or changes speed, you have to do it all over again. Many sailors skip using these tools because the setup is too cumbersome.My approach: zero required input.I think it's possible to build an software tool that can automatically learn your boat’s polars, detect wind shifts, remember the start line and marks, and track VMG—all in real time, with no button presses. It will recommend optimal tacks, track lifts and headers, and adapt as conditions change. Most importantly, the app will learn—the more you use it, the smarter it gets.<figure id="figure-syrsju8n7vmec0hg11"><img id="syrsju8n7vmec0hg11" src="https://cdn.durable.co/blocks/bANukNgih3FG9JlNV2dkOzWacsKIKX6q3A55nAuaQDdu8az1LkUVAkTbiZ6gDZ16.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/bANukNgih3FG9JlNV2dkOzWacsKIKX6q3A55nAuaQDdu8az1LkUVAkTbiZ6gDZ16.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>______________________________________________________________Phase 5: User TestingOnce Tactical Mode is functional, I’ll send test units to select sailors and gather feedback for refinement.______________________________________________________________Phase 6: Garmin Compatibility In parallel with testing, I’ll begin porting the app to Garmin devices because:- Advanced features will benefit from hardware buttons. - Supplemental data can be displayed on the watch. - Nearly every sailor I know owns one. - Small boat sailors often leave their phone ashore.______________________________________________________________Phase 7: Iteration &amp; Launch Using tester feedback, I’ll refine features and prepare a beta release on Android, iOS, and Garmin app stores.______________________________________________________________If you’re interested in collaborating, have feature suggestions, or want progress updates, reach out via the Contact Me page here or at SailView.co.<figure id="figure-ynli13p51fmec0ip2v"><iframe id="ynli13p51fmec0ip2v" src="https://www.youtube.com/embed/1A2eZtyaXHk" 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/1A2eZtyaXHk" data-corners="default" data-fullwidth="false" data-mce-src="https://www.youtube.com/embed/1A2eZtyaXHk" data-mce-style="aspect-ratio: 16/9;"></iframe></figure>

SailView  - Tactical AR Glasses

American Magic – Mechatronics Engineer: Human Machine Interface &amp; Simulation<h3>At a Glance</h3> Human Input Devices: Designed, prototyped, and built over 100 custom controllers (steering wheels, twist grips, flight/sail/cyclist controls) to meet evolving boat logic and rule changes. Dynamic Control Logic: Transitioned from AC36’s basic “push-to-trim” inputs to AC37’s linked, sensor-driven dynamic control systems. Crew Information Systems: Developed and tested multiple display systems, tactical layouts, cameras, AR concepts, and audio cues to maximize sailor performance. Simulator Development: Co-developed a hardware-in-the-loop sailing simulator mirroring the race boat’s PLC, CAN bus, and controls for both training and design validation. &nbsp;<h3><img id="awpugv53e7me8rwnog" src="https://cdn.durable.co/blocks/12SBGuaKCkvVU67gx28OLRHgnzTZeCrBtofoSqpdLvz8X2U9uCWHaxIpHuH8NiUp.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="" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/12SBGuaKCkvVU67gx28OLRHgnzTZeCrBtofoSqpdLvz8X2U9uCWHaxIpHuH8NiUp.jpg" data-mce-style="aspect-ratio: 16/9; object-position: undefined undefined;">The Role</h3>________________________________________________________________Engineering at the Edge: My Experience with American Magic in the 37th America’s Cup Chasing the America’s Cup is like working at a fast-paced startup. You have a crystal-clear goal, an immovable deadline, and a small, highly focused team compressing months of development into days. Long hours, rapid iteration, and constant innovation are the norm.During my time with American Magic, I worked at the intersection of mechanical, electrical, and software engineering — designing control systems, building cockpits, developing simulators, and ensuring our electro-mechanical systems could survive one of the harshest racing environments in the world.&nbsp; From Push-to-Trim to Closed-Loop Control When I joined the team, our AC36 yacht operated under strict “push-to-trim” rules — no feedback control, no preset target trims, no automation beyond holding a button to move the sail.However, the AC37 protocol changes were a huge evolution. While still limited, they now allowed closed-loop position feedback control. This meant:<ul><li>Pressing a button could send a sail to a preset position.</li><li>Different trim configurations could be loaded and recalled.</li><li>Smart lookup tables could link control functions — for example, trimming sails as a function of foil cant or having the jib and main trim proportionally.</li></ul>We still couldn’t use external environmental sensors or yacht state for fully automatic trimming — adjusting sails based on wind speed or boat speed was prohibited. But by designing clever sailor-driven inputs, we gave the boat partial awareness of its state and the surrounding conditions. This “dynamic control logic” became a foundation for much of my later work.&nbsp; Rethinking the Cockpit Traditional sailing has one driver, one trimmer, one flight controller, with crew crossing the boat during maneuvers. We decided this movement disrupted focus at the most critical race moments.Our solution: keep sailors in place for the entire race. Two dedicated drivers stayed on their sides, and trimmers/flight controllers switched roles based on position. This allowed us to:<ul><li>Design cockpits around each sailor, like a Formula 1 car or fighter jet.</li><li>Tailor ergonomics and control layouts to individual preferences.</li><li>Integrate the new closed-loop control logic directly into the hardware.</li></ul>Where old controllers were simple “press-to-trim,” the new ones would now feature position encoders, preset dials, twist grips, go-to-target buttons, and conditional logic.<figure id="figure-8v4ys62e19me8xk664"><img id="8v4ys62e19me8xk664" src="https://cdn.durable.co/blocks/1ajrhAYG5328UFEnGu4tBjO8UBnJDHaKuRg61nwbtE4tPhbf1j8RIl5GfZ0VtKbv.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/1ajrhAYG5328UFEnGu4tBjO8UBnJDHaKuRg61nwbtE4tPhbf1j8RIl5GfZ0VtKbv.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure> Human Interface Devices &amp; Rapid Prototyping Because of the fast pace, even racing hardware was often 3D-printed with high-quality SLS or made from hand-molded/CNC-machined carbon fiber. New controllers went from concept to deployment in 1–2 weeks.Highlights included:<ul><li>Formula 1-style steering wheels — custom grips molded to sailor hands, dozens of functions, displays, LEDs, encoders, paddle shifters.</li><li>Specialized trim controllers — from Xbox-style grips to motorcycle twist throttles.</li><li>Cyclor interfaces — enabling athletes producing 400+ watts of hydraulic power to also shift gears and input environmental data in near-real-time. </li></ul>This was hands-on, iterative engineering — designing, testing, and refining under race-ready deadlines.<figure id="figure-evhifiukjme8woy3r" class=""><img id="evhifiukjme8woy3r" src="https://cdn.durable.co/blocks/20VnZCkxrt7nHnUgEuopQDoVGEeHEvO0i3QtkjRtrGG8BQasdHs7clANpPlSn03z.png" alt="" title="" class="object-cover bg-gray-100 rounded-sm md:rounded-md lg:rounded-lg" style="aspect-ratio: 16/9; object-position: 50% undefined%;" data-corners="default" data-aspect="16:9" data-caption="image blured" data-positionx="50%" data-positiony="undefined%" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/20VnZCkxrt7nHnUgEuopQDoVGEeHEvO0i3QtkjRtrGG8BQasdHs7clANpPlSn03z.png" data-mce-style="aspect-ratio: 16/9; object-position: 50% undefined%;"><figcaption class="body-normal text-gray-500 mt-2">image blured</figcaption>&nbsp; </figure><figure class="">Building the Hardware-in-the-Loop Simulator In parallel, I contributed to development of our custom hardware-in-the-loop simulator for testing aerodynamic models, vehicle dynamics, electronic systems, control logic, and cockpit ergonomics. This simulator was also to serve as a training platform for the sailors.</figure>We converted two shipping containers into full-scale race pods:<ul><li>Identical controls, displays, and cockpits to the real boat</li><li>Hardware-in-the-loop testing with the same PLC and yacht computers as the race boat, connected over CAN bus.</li><li>AR/VR integration — sailors saw Barcelona’s harbor but also their actual physical controls. The simulator served both as an engineering testbed and a full training environment for sailors — used for evening practice and race-day warm-ups.</li></ul><figure id="figure-gomys98zvtme8yigt5"><img id="gomys98zvtme8yigt5" src="https://cdn.durable.co/blocks/cYLI8Z93AcZbV2b4VcFpoChEzMHdrpNcRZpCSqdDOYvcQk55oNYx46EmVRfApoIK.png" 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="image blurred" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/cYLI8Z93AcZbV2b4VcFpoChEzMHdrpNcRZpCSqdDOYvcQk55oNYx46EmVRfApoIK.png" data-mce-style="aspect-ratio: 16/9; object-position: undefined undefined;"><figcaption class="body-normal text-gray-500 mt-2">image blurred</figcaption></figure> Crew Information System &amp; Cognitive Load Management With crew pods positioned deep inside the boat for aerodynamic efficiency, direct visibility was minimal. We built a Crew Information System to give sailors full situational awareness:<ul><li>Panoramic displays — drivers could see all around the boat, flight controllers monitored foil arms, trimmers watched sail cameras.</li><li>Dynamic yacht visualizations — 3D models matched boat pitch/roll in real-time.</li><li>HUD smart glasses — presented 1–2 key data points without breaking focus from surrounding boats and tactics.</li><li>Audio cues, overlaid maps, peripheral LEDs — inspired by fighter pilot research. </li></ul>All of this complied with rules forbidding any manipulation of camera footage or data overlay on live video.<figure id="figure-ppmztwnxm8me8yh7sg"><img id="ppmztwnxm8me8yh7sg" src="https://cdn.durable.co/blocks/12w3ToV5YEhlom73Qs6TuTgWGqm2aUyg2eaZdUNeJ5PGP5wNr54UiWrMRgIiDC8T.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="image blurred" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/12w3ToV5YEhlom73Qs6TuTgWGqm2aUyg2eaZdUNeJ5PGP5wNr54UiWrMRgIiDC8T.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"><figcaption class="body-normal text-gray-500 mt-2">image blurred</figcaption></figure> Reliability in Extreme Conditions The AC75 is a wet, violent environment. Electronics were constantly exposed to:<ul><li>Saltwater immersion (sometimes minutes at a time during capsizes)</li><li>High heat (baking in 90°F sun)</li><li>Heavy mechanical shock and vibration </li></ul>Full potting for waterproofing was too heavy, so I created a QR-coded lifecycle tracking system for all cockpit electronics:<ul><li>Every controller scanned before sailing.</li><li>System logged total “sail days” and tracked the age of individual buttons, dials, and components.</li><li>Incident logs recorded all failures and repairs. </li></ul>The result was a color-coded health dashboard showing optimal controllers for race day. Data revealed the “sweet spot” for reliability: no controller should race before 6 sail days (break-in period) or after ~40 sail days (wear-out phase).<img id="m22vtogg8lme8xev6o" src="https://cdn.durable.co/blocks/165Zw6oYotAmbHvOiX2Q0JLKCbWZlDjSooqT6XUr3a3K3TZn3W5EqSJVPUnB4wGw.png" alt="" title="" class="object-cover bg-gray-100 rounded-sm md:rounded-md lg:rounded-lg" style="aspect-ratio: 16/9; object-position: 50% 15%;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="50%" data-positiony="15%" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/165Zw6oYotAmbHvOiX2Q0JLKCbWZlDjSooqT6XUr3a3K3TZn3W5EqSJVPUnB4wGw.png" data-mce-style="aspect-ratio: 16/9; object-position: 50% 15%;">Outcome: Zero cockpit electronics failures during three months of racing.&nbsp; Takeaways Working on American Magic was the ultimate proving ground for rapid prototyping, systems design, hardware-in-the-loop simulation, and human-machine interface innovation — all while balancing strict rule compliance, ergonomic performance, and extreme environmental reliability.It was fast-paced, high-pressure engineering — and exactly the kind of challenge I thrive on. Read more about my time with this campaign:WPI Journal Article: <a data-mce-href="https://wp.wpi.edu/journal/articles/the-race-for-the-auld-mug/" href="https://wp.wpi.edu/journal/articles/the-race-for-the-auld-mug/">Liam Shanahan and The Race for the 'Auld Mug'</a>

American Magic AC37

SailGP - Systems engineer for season 2-3 SailGP<h3>At a Glance</h3><ul><li>Upgraded &amp; maintained onboard control systems across fleet</li><li>Conducted pre-race systems checks to ensure every sensor, button, and actuator was operational.</li><li>Monitored live telemetry and onboard comms during races, diagnosing and advising on critical systems issues.</li><li>Coordinated rapid troubleshooting and repairs between races to maximize fleet reliability for live broadcasts.</li><li>Implemented fleet-wide control software upgrades to improve reliability and ease of maintenance.</li></ul>___________________________________________________________<figure id="figure-xph3qetnjvme91i4qe"><img id="xph3qetnjvme91i4qe" src="https://cdn.durable.co/blocks/38ik3CpofXQo3C42nJqz9JEfY2obfyeeUdoVu7WyeGtN425TTgkMznzeG7xNaFoE.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/38ik3CpofXQo3C42nJqz9JEfY2obfyeeUdoVu7WyeGtN425TTgkMznzeG7xNaFoE.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure><h3>My Role</h3>SailGP Overview SailGP is a global racing circuit featuring nine identical 50-foot foiling catamarans — ultra-high-performance, hydraulically powered, rigid-wing sailboats originally developed for the America’s Cup. Unlike the America’s Cup, where absolute performance can outweigh reliability, SailGP’s one-design format demands identical configurations, high reliability, and streamlined maintenance to ensure every boat makes the start line.&nbsp; Systems Integration &amp; Pre-Race Checks Each event took place in a new city, with the boats shipped, reassembled, and made race-ready in just days. Once mechanical, hydraulic, and electrical teams completed their checks, I served as the final systems gatekeeper — verifying that every sensor, button, hydraulic ram, and software-controlled function worked seamlessly together. These integration checks ensured all systems were aligned before rolling the boats out for racing.<figure id="figure-vifgrqv0gqme91n3fk"><img id="vifgrqv0gqme91n3fk" src="https://cdn.durable.co/blocks/1al4x25bvxErtAQViagTsYanIwgh7HpjlE2l648ilpos6v1mbZd5HiVmZJXrerlw.jpg" alt="" title="" class="object-cover bg-gray-100 rounded-sm md:rounded-md lg:rounded-lg" style="aspect-ratio: 16/9; object-position: 50% 25%;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="50%" data-positiony="25%" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/1al4x25bvxErtAQViagTsYanIwgh7HpjlE2l648ilpos6v1mbZd5HiVmZJXrerlw.jpg" data-mce-style="aspect-ratio: 16/9; object-position: 50% 25%;"></figure> Live Telemetry &amp; On-Water Support During racing, I worked from the Systems Command Center, monitoring real-time data from the fleet using a Cosworth control and diagnostics system (adapted from motorsports). If a fault occurred — like a board not raising when commanded — I had seconds to diagnose the cause from telemetry, communicate with the crew, and recommend an immediate fix. This rapid decision-making was critical in the tense minutes before a race start, often under live TV coverage.<figure id="figure-4ajyvkpufsme91damp"><img id="4ajyvkpufsme91damp" src="https://cdn.durable.co/blocks/bO0XN5qUsz9Q6MB1ihMr1m1DUgHpLdMiRMzsjvoOVG0BwQBoJGSepw0j3aHpaLkD.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/bO0XN5qUsz9Q6MB1ihMr1m1DUgHpLdMiRMzsjvoOVG0BwQBoJGSepw0j3aHpaLkD.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>&nbsp; Post-Race Troubleshooting &amp; Upgrades After racing, I gathered feedback from sailors, reviewed logs, and diagnosed any reported issues. Some fixes were straightforward, like swapping a failed sensor. Others involved deeper software updates, configuration changes, or hardware adjustments that had to be rolled out to the entire fleet. Our small three-person systems team often worked late into the night to ensure every boat was ready for the next day’s racing.Between events, I collaborated on system upgrades to improve reliability, reduce maintenance time, and scale the fleet’s operational readiness as the league grew.&nbsp; Impact &amp; Skills This role combined high-pressure troubleshooting, systems integration, fleet-wide upgrades, and global event support. It gave me extensive experience in:<ul><li>Real-time fault diagnosis and high-pressure decision making </li><li>Integrating complex mechanical, hydraulic, and software systems</li><li>Delivering reliability improvements to high-performance technology</li><li>Supporting complex electro-mechanical systems in harsh marine environments<figure id="figure-cbg5vn59zgeme91ur7d" class=""><img id="cbg5vn59zgeme91ur7d" class="bg-gray-100 object-cover" style="aspect-ratio: 16/9;" data-mce-style="aspect-ratio: 16/9;"></figure></li></ul>

SailGP

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

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

USAF - Aircraft Systems Engineer<h3>At a Glance </h3><ul><li>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"><img id="46fom07rfimea81e2f" src="https://cdn.durable.co/blocks/24Wt2wgy2hBzUviY7nMGLPM3EX71TWH2GF0Nm1l6pmHmhBHJAvZpYmXE6KkciY1Q.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% 50%;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="undefined%" data-positiony="50%" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/24Wt2wgy2hBzUviY7nMGLPM3EX71TWH2GF0Nm1l6pmHmhBHJAvZpYmXE6KkciY1Q.jpg" data-mce-style="aspect-ratio: 16/9; object-position: undefined% 50%;"></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)

Contact form

<h3>Contact Liam to Discuss Projects</h3>
Get in touch with ideas, projects, questions, or musings of any kind.