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Electric Hydrofoil Surfboard BuildAt a Glance <ul><li>Built a custom electric hydrofoil surfboard from scratch</li><li>Integrated high-voltage LiPo batteries, water-cooled ESC, and DC motor</li><li>Designed “wet-run” motor housing with 3D-printed cooling system</li><li>Created parametric 3D propeller for rapid testing</li><li>Flush-mount electronics with LCDs + safety kill switch</li></ul><figure id="figure-lwqtolcm3kmebmzpdr" class=""><iframe id="lwqtolcm3kmebmzpdr" src="https://www.youtube.com/embed/-VPDS6gOjFc" 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/-VPDS6gOjFc?si=H0nnzwki6PZf8ZRM" data-corners="default" data-fullwidth="false" data-mce-src="https://www.youtube.com/embed/-VPDS6gOjFc" data-mce-style="aspect-ratio: 16/9;"></iframe></figure>__________________________________________________________________<h3>Project Summary:</h3>Around 2019, the remote-controlled electric hydrofoil surfboard was just starting to capture the attention of a few small companies and a handful of hobbyists. As both a surfing and engineering enthusiast, I was hooked on the idea—riding above the water on any lake or bay, without relying on wind or a boat for towing. It felt like the natural next step from my earlier obsession with building high-powered electric skateboards, only now the challenge was bigger: more power, higher voltages, streamlined hydrodynamics, and serious waterproofing, all hidden inside the thinnest board possible.<figure id="figure-7gbn04gozmmebnzn0x"><img id="7gbn04gozmmebnzn0x" src="https://cdn.durable.co/blocks/0HzrJNqqsnplYVdETdLHymJPcEAiktvbrZFjlRxin00gTodRgsujcoEh0Tugo2fJ.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/0HzrJNqqsnplYVdETdLHymJPcEAiktvbrZFjlRxin00gTodRgsujcoEh0Tugo2fJ.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>One big design challenge was runtime. My skateboards could cruise for six hours, but even the best foil boards topped out around 45 minutes. I started with two massive 10 Ah LiPo batteries, paired with a top-of-the-line water-cooled RC boat speed controller, a large DC motor, a battery management system, and the necessary fuses, thermometers, and kill switches.&nbsp;<figure id="figure-j0iairxo8nmebo0dmr"><img id="j0iairxo8nmebo0dmr" src="https://cdn.durable.co/blocks/16ACPmFDv9qVVwYEzb4LiY5txoFKG6sbWbfj1Yx9SRnEAoKtYNZkTmUjlLs6qXjg.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/16ACPmFDv9qVVwYEzb4LiY5txoFKG6sbWbfj1Yx9SRnEAoKtYNZkTmUjlLs6qXjg.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>For the board itself, luck struck—my neighbor was getting rid of a 12.5-foot fiberglass racing windsurf board. At 6.5 inches thick in its center section, it was just barely deep enough to conceal the battery box.<figure id="figure-32riwqna8jmebo4ehp"><img id="32riwqna8jmebo4ehp" src="https://cdn.durable.co/blocks/6uefSgNukkkqnBZtqcDtgSA44nhez3ddiE6AtHMfasT0M69atByuKIXYiMJfRyuw.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/6uefSgNukkkqnBZtqcDtgSA44nhez3ddiE6AtHMfasT0M69atByuKIXYiMJfRyuw.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure> I cut it so the thickest part was at the rear for battery placement near the center of rotation, with the speed controller, pump, and other electronics forward of that. This layout gave me direct access to the foil mast for running both wiring and water-cooling lines to the motor.<figure id="figure-puh6vzbjsbmebo76c6"><img id="puh6vzbjsbmebo76c6" src="https://cdn.durable.co/blocks/9DuHSA4YkBJMb2Y56dtDcSnqvNxoFLDL5Cmqo67uMrVrKmWbvHgC8tUvfV132BIH.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% 50%;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="50%" data-positiony="50%" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/9DuHSA4YkBJMb2Y56dtDcSnqvNxoFLDL5Cmqo67uMrVrKmWbvHgC8tUvfV132BIH.jpg" data-mce-style="aspect-ratio: 16/9; object-position: 50% 50%;"></figure>Rather than strapping Pelican cases to the deck like many hobbyists, I wanted a cleaner, more integrated look. I sourced two low-profile boxes that sat flush with the deck, covering them with foam grip tape. The motor was another interesting design challenge—fully sealed motors risk overheating, so I decided to run mine “wet.” I disassembled the outrunner, coated the coils and magnets in layers of conformal coating, and built a custom threaded aluminum housing with a 3D-printed nose cone and prop shroud. The nose cone had intake holes to channel water through the motor for active cooling before exiting at the tail.<figure id="figure-eexu3c0ky4meboews7" class=""><iframe id="eexu3c0ky4meboews7" src="https://www.youtube.com/embed/KOXruQnSbQE" 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/KOXruQnSbQE" data-corners="default" data-fullwidth="false" data-mce-src="https://www.youtube.com/embed/KOXruQnSbQE" data-mce-style="aspect-ratio: 16/9;"></iframe></figure>Designing the propeller was a mix of math and experimentation. I created a parametric 3D model that let me quickly test blade counts, angles, and diameters, all inside a protective shroud. For the speed controller, I ran the three large-gauge motor phase wires down the mast along with a single vinyl tube to pump cooling water from the foil’s nose cone back up to the ESC’s sealed housing.<figure id="figure-tlb4stm14hmebojyhp"><img id="tlb4stm14hmebojyhp" src="https://cdn.durable.co/blocks/2a9cP4wMY6tS9kmWmzjoUQaKUyWBqNesMgdM9gBCM7tEwryx8pKpUDPO2N1Qm4fx.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/2a9cP4wMY6tS9kmWmzjoUQaKUyWBqNesMgdM9gBCM7tEwryx8pKpUDPO2N1Qm4fx.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>Safety was a priority. I mounted LCD displays to monitor battery percentage, power draw, and internal temperatures, and added a jet-ski-style kill switch and lanyard to instantly cut power if I fell—preventing the nightmare scenario of an unattended spinning prop.<figure id="figure-voeocvahfjmebouhg3"><img id="voeocvahfjmebouhg3" src="https://cdn.durable.co/blocks/36gx949CoK6YrBkEpAL3UscBjKtvKFFH4xcNM7kS7ytTwAT2hERW6l9Bavi5zKUD.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/36gx949CoK6YrBkEpAL3UscBjKtvKFFH4xcNM7kS7ytTwAT2hERW6l9Bavi5zKUD.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>The board worked, but it taught me hard lessons. Space inside the battery box was too tight, making maintenance and fuse changes difficult. More importantly, it was my first real dive into waterproofing, and despite meticulous sealing, water eventually found its way in through the many cutouts for buttons, screens, and ports.<figure id="figure-wnq5a5imlfmebowu0g"><img id="wnq5a5imlfmebowu0g" src="https://cdn.durable.co/blocks/32BJI8KZkUkfeeu41jfMrCZE1Qv3PtfdWnWaxIgue0gh83CUyU2SwRVKSgu2tbf5.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/32BJI8KZkUkfeeu41jfMrCZE1Qv3PtfdWnWaxIgue0gh83CUyU2SwRVKSgu2tbf5.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>In later years—through projects in far harsher marine environments—I learned that long-lasting waterproof design means minimizing cable penetrations, using only proven military-grade connectors, sealing critical electronics with RT-125 potting compound, and replacing physical switches with magnetic or hall-effect sensors wherever possible. This project was the start of that education—an ambitious, fun build that merged my love for surfing, engineering, and the challenge of making electronics survive in the ocean. <figure id="figure-ugmafw212wmebop4pc" class=""><iframe id="ugmafw212wmebop4pc" src="https://www.youtube.com/embed/BTaf1sAB9nU" 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/BTaf1sAB9nU" data-corners="default" data-fullwidth="false" data-mce-src="https://www.youtube.com/embed/BTaf1sAB9nU" data-mce-style="aspect-ratio: 16/9;"></iframe></figure>

E-Foil Surfboard

<h3>At A Glance&nbsp;&nbsp; </h3><ul><li>Designed systems architecture for a fully autonomous 2 m sailboat.</li><li>Built a rigid wingsail with integrated wind sensing and self-trimming control.</li><li>Developed CFD-optimized hull for speed, stability, and internal systems space.</li><li>Optimized actuator control for improving responsiveness and sailing performance.</li><li>Implemented CAN-bus network linking onboard computer, sensors, and controllers.</li><li>Received WPI Povost Award for best senior capstone project in Robotics Engineering.&nbsp;</li><li>Recieved first place finish at the 2018 International Robotic Sailing Regatta<figure id="figure-mr4nhgbp2meafjt9r"><img id="mr4nhgbp2meafjt9r" src="https://cdn.durable.co/covers/23tcdiQYoLtdJhFYAmM0isuclXSW8DsMQ44wSU8IdfkjWqj2HKV0506lyJKTwsth.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/covers/23tcdiQYoLtdJhFYAmM0isuclXSW8DsMQ44wSU8IdfkjWqj2HKV0506lyJKTwsth.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure></li></ul>_______________________________________________________________<h3>SailBot</h3>The goal of the <a data-mce-href="https://www.sailbot.org/" href="https://www.sailbot.org/">International Robotic Sailing Regatta</a> is to design a 2m long boat that can autonomously race through a 1-mile long course as well as perform a variety of other navigational tasks.&nbsp; &nbsp;&nbsp; This was a continuation of a previous years project that had done fairly well in the competition. However, In our first project meeting, my 3 teammates and I decided on the lofty goal that we would be designing and building:<table style="border-collapse: collapse; width: 100%;" border="1" data-mce-style="border-collapse: collapse; width: 100%;"><tbody><tr><td style="width: 100%;" data-mce-style="width: 100%;">- new hull - new steering system - re-designed navigation system - new movable ballast - new rigid wingsail - new composite cloth sail&nbsp; - new vision-based obstacle avoidance system - re-designed optimal path trajectory planning&nbsp;</td></tr></tbody></table>HOW IT WORKS: &nbsp; Disclaimer: The purpose of this article isn’t to get too far into the nitty-gritty of how this thing actually functions. However, If you are interested, you can find much more technical detail <a data-mce-href="https://drive.google.com/file/d/1tJh_7k-V9GA9tBCHJ5aivlckRLlH020q/view?usp=sharing" href="https://drive.google.com/file/d/1tJh_7k-V9GA9tBCHJ5aivlckRLlH020q/view?usp=sharing">HERE</a> in our complete report of the project.&nbsp;The Hull:&nbsp; &nbsp; The geometry of the hull was designed with packaging, ballast, and sailing dynamics in mind. The bow and stern profiles of the hull were derived from modern, high-performance yachts such as the Imoca 60 and the Volvo 65. These boat designs have proven to be light, stable, efficient, and seaworthy in all sailing conditions.<figure id="figure-ueqjq87s2hmeagw8jp"><img id="ueqjq87s2hmeagw8jp" src="https://cdn.durable.co/blocks/18dHmhIwZvqTxCQl2h00xAiP5muJsJxOny32UHDLHedEqfIxvs8xsGzuqKqc14Qw.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/18dHmhIwZvqTxCQl2h00xAiP5muJsJxOny32UHDLHedEqfIxvs8xsGzuqKqc14Qw.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>While speed and seaworthiness were important we mostly needed to make sure this hull would be able to house all of the hardware, sensors, and cabling we would need to control it.&nbsp;<figure id="figure-adxgp5573ameag0jty" class=""><img id="adxgp5573ameag0jty" src="https://cdn.durable.co/blocks/1eMSSJ7YnBJ4N0uC5qehzS9DwUv8XLTimWBvjfFZeX4vvyVXnhKzhhgAwJKRAdXG.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/1eMSSJ7YnBJ4N0uC5qehzS9DwUv8XLTimWBvjfFZeX4vvyVXnhKzhhgAwJKRAdXG.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>So we ran several CFD simulations to optimize the shape and ensure it would pass throught he water without creating inwanted vorteces.The Wingsail:&nbsp; &nbsp; We decided that if we were going to build a high-tech boat, we might as well also build the most advanced sail possible as well. We decided to make a wingsail that was completely self-contained, self-trimming, and wirelessly connected to the boat.&nbsp;<figure id="figure-ppmr4bkqy9meag3qj3"><img id="ppmr4bkqy9meag3qj3" src="https://cdn.durable.co/blocks/2elDQDrcAZ3JQrNZOSksCoC0K7tZJfxcAwRNo2PAzXKeDBCCxIxDAM1cNIhGpd3L.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/2elDQDrcAZ3JQrNZOSksCoC0K7tZJfxcAwRNo2PAzXKeDBCCxIxDAM1cNIhGpd3L.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure> With such a complex wingsail comes lots of risk, and we would need a backup sail. However, if we were going to make a backup sail, we might as well make the best backup sail imaginable. So, with the help of Chris Williams, an engineer at Quantum Sails, and Taylor North, from Dimension Polyant, we constructed another badass sail constructed from aramid impregnated composite sailcloth.&nbsp; &nbsp; The Cloth Sail:<figure id="figure-ia0jl1rvaimeag7549" class=""><img id="ia0jl1rvaimeag7549" src="https://cdn.durable.co/blocks/3nNgVsWZPP8Los3E9rEB7hzHOmtUj36TTjuD9kT7yOO2VdnS8QcWqbBV9DFwOxmB.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/3nNgVsWZPP8Los3E9rEB7hzHOmtUj36TTjuD9kT7yOO2VdnS8QcWqbBV9DFwOxmB.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>Now, what's a sailboat without your rail meat crew running from side to side of the boat. We'll, our solution to this was a mechanical arm that would swing a lead ball back and forth to always keep the boat at exactly 10 degrees of leeward heel.<figure id="figure-4d44tntxctmeagcqxg" class=""><img id="4d44tntxctmeagcqxg" src="https://cdn.durable.co/blocks/16lRRVxXi797QpgQgaKAIxqyTTVaAc7UMPfEPb0GZMQib99htfA57eWDFgygnonW.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/16lRRVxXi797QpgQgaKAIxqyTTVaAc7UMPfEPb0GZMQib99htfA57eWDFgygnonW.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>Now, it need not be said that the electronics and control architecture of this boat could fill a book of it's own, here is an overview of a bit of the inner workings of the control and navigation.Control Overview:<figure id="figure-t8ngh26mj8meagknpt"><img id="t8ngh26mj8meagknpt" src="https://cdn.durable.co/blocks/2fbqayy7C82VohqCevLUplj63HSpKsjOSXPV0pyriGhRlchlrKroHZJiAP03iJIN.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/2fbqayy7C82VohqCevLUplj63HSpKsjOSXPV0pyriGhRlchlrKroHZJiAP03iJIN.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>Essentially, there are many different sensors and motors mounted to the boat acting as a node on our CAN bus. The computer we used to manage all these nodes was a BeagleBone Black. The beaglebone runs multiple processes which communicate using a publish/subscribe architecture which shares messages between individual processes, or nodes. The Primary Control Node controls the path planning and overall decision making of the robot. The State Estimator Node provides the wind, heading, and position data, which is used to produce motor control outputs. The CAN Node communicates these outputs to the motor controllers on the CAN bus. Additional nodes are used for logging and debugging via a web interface.&nbsp; Navigation:A really cool part of the boat is the way it actually new how to perform these tasks automatically. In essence, the boat could be wirelessly connected to our laptop where GPS waypoints could be assigned to it. The boat would then use it's onboard wind sensor data to calculate an optimal sailing angle and sail trim to tack, gybe, and navigate to those positions. Then, when the boat came within a close enough proximity to the point (buoys in this case, it used computer vision to identify the marks. This "rounding procedure" helped the boat to round a mark closely but without hitting it. It also allowed the boat to sail far enough to layline instead of getting stuck directly downwind of a windward mark for example.&nbsp;<figure id="figure-q39fh7qbdgmeagukqg"><img id="q39fh7qbdgmeagukqg" src="https://cdn.durable.co/blocks/eJGapPT6EZQ96YkBqLXGJLsueYZ5iOlNGmdarsJtjOTVD1ClRBfnGZ5tMO9jv9gL.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/eJGapPT6EZQ96YkBqLXGJLsueYZ5iOlNGmdarsJtjOTVD1ClRBfnGZ5tMO9jv9gL.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>In the end, not only did we create a well-equipped high-performance boat, but all of our work led us receiving the WPI Provost award for best robotics capstone projecte.&nbsp; Whe then continued on to win first place in the 2018 International Robotic Sailing Regatta. I learned a lot from this project and took away a new appreciation for the difficulties and applications of autonomous, on water navigation. Read More About this Project: <a data-mce-href="https://drive.google.com/file/d/1tJh_7k-V9GA9tBCHJ5aivlckRLlH020q/view?usp=sharing" href="https://drive.google.com/file/d/1tJh_7k-V9GA9tBCHJ5aivlckRLlH020q/view?usp=sharing">Official WPI Project Report</a><a data-mce-href="https://www.wpi.edu/news/sailbot-combines-robotics-and-sailing-challenges" href="https://www.wpi.edu/news/sailbot-combines-robotics-and-sailing-challenges">SailBot Combines Robotics and Sailing Challenges</a> <figure id="figure-rd2zvyudbmeah0u7e"><img id="rd2zvyudbmeah0u7e" src="https://cdn.durable.co/blocks/e4X0cRacoDE3SF6kzJkeXcxzHCoCQuB1TZiIa2m4j8qOJ3lj3HO8FfSOWf1TrrXN.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/e4X0cRacoDE3SF6kzJkeXcxzHCoCQuB1TZiIa2m4j8qOJ3lj3HO8FfSOWf1TrrXN.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>

Autonomous Sailboat

ClearMotion – Systems Engineering Internship <h3>At a Glance </h3><ul><li>Supported the Head of Systems Engineering in implementing the V-model development framework to unify cross-disciplinary automotive teams.</li><li>Built Atlassian-based project tracking, ticketing, and requirements management tools to establish traceability across electrical, mechanical, and software domains.</li><li>Created baseline documentation to accelerate development cycles while meeting stringent automotive standards.<figure id="figure-rzvv3d5ixmebktzpn" class=""><img id="rzvv3d5ixmebktzpn" src="https://cdn.durable.co/blocks/2ew1uSuiREc1SGHKjZb6PQCW3zwJhPRXQXSXBY80lfoFjvNmdG1iFK8jodTeJjeV.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/2ew1uSuiREc1SGHKjZb6PQCW3zwJhPRXQXSXBY80lfoFjvNmdG1iFK8jodTeJjeV.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure></li></ul>________________________________________________________________<h3>My Role</h3> When I joined ClearMotion it was still a startup out of MIT. The company was in the midst of rapid growth—approaching 100 employees—and was scaling its active suspension technology for luxury vehicles. The system combined high-performance actuators, sensors, and control software to actively counteract bumps and body roll, delivering a smooth, controlled ride. This was a complex, safety-critical product involving electrical, mechanical, software, and compliance teams, all needing to work in sync.I worked directly under the new Head of Systems Engineering, whose mission was to introduce the <a href="https://en.wikipedia.org/wiki/V-model" data-mce-href="https://en.wikipedia.org/wiki/V-model">V-model</a> development process to streamline coordination. In the automotive world, the V-model is a structured, traceable engineering framework:<figure id="figure-e9c2bxpcamebkrut3"><img id="e9c2bxpcamebkrut3" src="https://cdn.durable.co/blocks/2adBoDG9l9diT9q6y3P3TFq97GZP4y8tVWcO0CNesWCmzshqn1QAkXqPXeZV6tK8.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/2adBoDG9l9diT9q6y3P3TFq97GZP4y8tVWcO0CNesWCmzshqn1QAkXqPXeZV6tK8.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure><ul><li>On the left side of the V, requirements are defined at progressively detailed levels—starting from high-level customer needs, through system specifications, to detailed component designs.</li><li>On the right side, each stage has a corresponding integration and verification step, ensuring that every requirement is validated against the original objectives.</li><li>The horizontal links across the V enforce traceability, so that every design decision and test can be tied back to a requirement, and vice-versa. </li></ul>My work focused on making the V-model real inside the organization. This included:<ul><li>Designing Atlassian Jira/Confluence workflows for requirements tracking, linking each ticket to its associated verification activities.</li><li>Creating requirements management baselines to capture the agreed-upon starting point for each design iteration. Setting up project timelines and dashboards so engineering teams could see dependencies across disciplines and work toward common milestones.</li><li>Supporting systems architecture development to ensure the active suspension could adapt to different vehicle platforms while meeting ISO 26262 functional safety guidelines. </li></ul>The result was a more unified development process where mechanical, electrical, and software engineers could work rapidly, yet with clear alignment and compliance readiness—a critical foundation for bringing a complex automotive technology to market. Read More Here: https://www.clearmotion.com/how-it-works<figure id="figure-acnhdsbj8mebkzpxp"><img id="acnhdsbj8mebkzpxp" src="https://cdn.durable.co/blocks/eXEdDIcjO5uNo77kgPPZb378sLjdPWIArcCBErV9WA0rqP9mtiMukOcoWJlfbc3x.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/eXEdDIcjO5uNo77kgPPZb378sLjdPWIArcCBErV9WA0rqP9mtiMukOcoWJlfbc3x.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>

ClearMotion

All the craze in 2017 was building electric skateboards, and I was deep in that world. I was about to spend a semester working in Denmark, and I wanted to build myself a stylish, portable method of transportation.The components were relatively simple, but the challenge was mounting them all neatly to the bottom of a skateboard.<figure id="figure-7yyjjfpwemebtkqpt"><img id="7yyjjfpwemebtkqpt" src="https://cdn.durable.co/blocks/17eVoEwKwLberhaAx7yBIUqjEO9mKXZ5Gb1Itsyjc4MsX9fTNSzSzs6f0vD8IduE.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/17eVoEwKwLberhaAx7yBIUqjEO9mKXZ5Gb1Itsyjc4MsX9fTNSzSzs6f0vD8IduE.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>The board consisted of:A large RC airplane brushless outrunner motor, bolted to a custom bracket welded to the back truck. The wheel was belt-driven from a pinion on the motor to a 3D-printed gear mounted to the inside of the wheel.<figure id="figure-l97zhp4ugjmebtlx7f"><img id="l97zhp4ugjmebtlx7f" src="https://cdn.durable.co/blocks/18tP3dT3yKJYc6aSqUV2PYhf2UzobrAPFM4ZqeNAT6MhnlSnjeILdSv4vO4WEr5f.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% 50%;" data-corners="default" data-aspect="16:9" data-caption="" data-positionx="50%" data-positiony="50%" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/18tP3dT3yKJYc6aSqUV2PYhf2UzobrAPFM4ZqeNAT6MhnlSnjeILdSv4vO4WEr5f.jpg" data-mce-style="aspect-ratio: 16/9; object-position: 50% 50%;"></figure>The motor ran to an electronic speed controller, which I mounted inside a custom aluminum housing. I had machined this housing with fins for maximum heat dissipation from the speed controller. The controller was designed so you could easily tune the acceleration curve of the board, avoiding the jerky motions that many RC devices have.<figure id="figure-g3fnqf0pn7mebtnvxe"><img id="g3fnqf0pn7mebtnvxe" src="https://cdn.durable.co/blocks/38VYqOxxgFzAHkcNHrBxcKKQLAsVDpypL7vE5LaBq4mo5Lx0o5D5F5bvKCDoR4np.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/38VYqOxxgFzAHkcNHrBxcKKQLAsVDpypL7vE5LaBq4mo5Lx0o5D5F5bvKCDoR4np.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>From there, the speed controller cables ran to the battery box, which held four large 5200 mAh batteries. These were configured into two large 8S batteries in parallel, running through an 8S BMS.<figure id="figure-bhbdag1bmmebu25yo"><img id="bhbdag1bmmebu25yo" src="https://cdn.durable.co/blocks/38agAjjTVmX688RClFH7zIJcB5JJcZHBQOen27BFb7mLyWXzsVfrX12g1L0yJ134.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="BMS cables are a pain" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/38agAjjTVmX688RClFH7zIJcB5JJcZHBQOen27BFb7mLyWXzsVfrX12g1L0yJ134.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"><figcaption class="body-normal text-gray-500 mt-2">BMS cables are a pain</figcaption></figure>The battery box had two cables sticking out of it: one for the charger and one with a small removable key connector that served as an ignition key.All of this was controlled with a small RC receiver and a simple thumb joystick.I finished the project just in time to take it to Denmark, where I’d go on eight-hour adventures, cruising through the city’s bike lanes. When I wanted to go inside a museum or restaurant, I could just pick up my board and carry it in.<figure id="figure-zvprzxn9ppmebu3xcm"><img id="zvprzxn9ppmebu3xcm" src="https://cdn.durable.co/blocks/140Hk8S1hQIwstnl7Zwk20zNK0jCvEzGSZXhV6j9TZeEchIu79IVXG7vGoTin1E8.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/140Hk8S1hQIwstnl7Zwk20zNK0jCvEzGSZXhV6j9TZeEchIu79IVXG7vGoTin1E8.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>This might be my favorite thing I’ve ever built—not only because it was one of my first real entries into electromechanical systems, but because it was so simple, reliable, and fun to ride. I had hundreds of hours of adventures on that thing.<figure id="figure-eivt9fmtnpmebuawhj"><img id="eivt9fmtnpmebuawhj" src="https://cdn.durable.co/blocks/271QpB9yunji1SkfHINkqT7oTW9vUTur5N5POKdDr3kiNKgsadACKz49XzvHPNWi.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/271QpB9yunji1SkfHINkqT7oTW9vUTur5N5POKdDr3kiNKgsadACKz49XzvHPNWi.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure>The board ended up being so reliable that it has survived hundreds of miles of runtime—and it’s still kicking today.__________________________________________________________________<figure id="figure-7lvodfuvrkmebubouz"><img id="7lvodfuvrkmebubouz" src="https://cdn.durable.co/blocks/fhOS4Fao7SMpToJM2VdsIKMzH8MWcxmAuU3gyBYv6Utznh60AcpbkonCnClv69ub.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="Two other friends joined in with their own builds" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/fhOS4Fao7SMpToJM2VdsIKMzH8MWcxmAuU3gyBYv6Utznh60AcpbkonCnClv69ub.jpg" data-mce-style="aspect-ratio: 16/9; object-position: undefined undefined;"><figcaption class="body-normal text-gray-500 mt-2">Two other friends joined in with their own builds</figcaption></figure><figure id="figure-jjxfc8uxomebuc8rx"><img id="jjxfc8uxomebuc8rx" src="https://cdn.durable.co/blocks/32Qu8e4u9GXeNyTjWrjRLzZAYMA2lXnpgzWb5ph8USpmKstpZvyy4TkR6098NBEn.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/32Qu8e4u9GXeNyTjWrjRLzZAYMA2lXnpgzWb5ph8USpmKstpZvyy4TkR6098NBEn.jpg" data-mce-style="aspect-ratio: 16/9; object-position: center center;"></figure><figure id="figure-6u0938zqgmebuczmy"><img id="6u0938zqgmebuczmy" src="https://cdn.durable.co/blocks/1cEk4DV4zXAcjXMPe3JaIX5fBxlQyTbrUTkiTLCJOMbE0XSTPf49cpvmASbHZEG4.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="Custom bracket to hold the motor in line with the wheel" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/1cEk4DV4zXAcjXMPe3JaIX5fBxlQyTbrUTkiTLCJOMbE0XSTPf49cpvmASbHZEG4.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"><figcaption class="body-normal text-gray-500 mt-2">Custom bracket to hold the motor in line with the wheel</figcaption></figure><figure id="figure-c7pdwgyanimebuhe0j"><img id="c7pdwgyanimebuhe0j" src="https://cdn.durable.co/blocks/32jIQyijA4P93GJvM4ZeGiHYbUIMengE51rPXD8d3pPx9BAfuFD2udQ4qcoN1syh.png" alt="" title="" class="object-cover bg-gray-100 rounded-sm md:rounded-md lg:rounded-lg" style="aspect-ratio: 1/1; object-position: center center;" data-corners="default" data-aspect="1:1" data-caption="Customized all the way down to the belt drive system" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/32jIQyijA4P93GJvM4ZeGiHYbUIMengE51rPXD8d3pPx9BAfuFD2udQ4qcoN1syh.png" data-mce-style="aspect-ratio: 1/1; object-position: center center;"><figcaption class="body-normal text-gray-500 mt-2">Customized all the way down to the belt drive system</figcaption></figure>

Electric Skateboard Build

In college, my job durring school was to TA for the CNC manifacturing and prototyping course. I served as a lab monitor for the Washburn Prototyping Shops, and I taught the labs for the Intro To Prototyping class.&nbsp; Below are the list of equipment I used frequently within this lab:<ul><li>Haas CNC milling machines (3 axis and 5 axis)</li><li>CNC lathe (3 axis and 6 axis)</li><li>Manual machinery, mills, lathes, sheers, welders, etc</li><li>Laser cutters</li><li>3D Printers (FDM, SLA Carbon composite)</li></ul>Takeaway: This experience gave me a really good understanding of how to design for manufactuability. I wouldn't realize how rare of a skill this was until i started working at companies where i was getting my parts manufactured at a fraction of the cost of my co-workers.&nbsp; Here are some of the things I built:<figure id="figure-cm6b9hy2sqmebm1v78"><img id="cm6b9hy2sqmebm1v78" src="https://cdn.durable.co/blocks/14YKM1ckTC6tP8m3KrZuhYwgLQNi9ic4hhdZtEP6ziDk2kPTN3X4qd2s9khPVDDJ.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="Gearbox for Robot Sailboat Movable Balast" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/14YKM1ckTC6tP8m3KrZuhYwgLQNi9ic4hhdZtEP6ziDk2kPTN3X4qd2s9khPVDDJ.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"><figcaption class="body-normal text-gray-500 mt-2">Gearbox for Robot Sailboat Movable Balast</figcaption></figure><figure id="figure-0ih27s0rlumebmm6so"><img id="0ih27s0rlumebmm6so" src="https://cdn.durable.co/blocks/220s9K8rU4F7JHxdcnFwfpnmymLJcXm0GQUGxWETmMrQzQH6ZFFSeu03iP8DttWq.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="Skate For Kitewing" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/220s9K8rU4F7JHxdcnFwfpnmymLJcXm0GQUGxWETmMrQzQH6ZFFSeu03iP8DttWq.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"><figcaption class="body-normal text-gray-500 mt-2">Skate For Kitewing</figcaption></figure><figure id="figure-8703pqlj7amebmn648"><img id="8703pqlj7amebmn648" src="https://cdn.durable.co/blocks/12Ac2JRWv143eJGpmHJ2awHUMFUtWR4y71Z2ExEls4VyYlhzmlLJAEFkXskVKSzG.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="Motor Mount for Electric Skateboard" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/12Ac2JRWv143eJGpmHJ2awHUMFUtWR4y71Z2ExEls4VyYlhzmlLJAEFkXskVKSzG.png" data-mce-style="aspect-ratio: 16/9; object-position: undefined undefined;"><figcaption class="body-normal text-gray-500 mt-2">Motor Mount for Electric Skateboard</figcaption></figure><figure id="figure-ncypcsdfkmebmonb6"><img id="ncypcsdfkmebmonb6" src="https://cdn.durable.co/blocks/18Jhn58hOFgkJUuUvqOs34rTgiB9AFv551j1sU8gngalXSXG8DCeaR26KwbOGwxF.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="Bevel for Sharpening Race Skis" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/18Jhn58hOFgkJUuUvqOs34rTgiB9AFv551j1sU8gngalXSXG8DCeaR26KwbOGwxF.png" data-mce-style="aspect-ratio: 16/9; object-position: center center;"><figcaption class="body-normal text-gray-500 mt-2">Bevel for Sharpening Race Skis</figcaption></figure><figure id="figure-eu24z8ibtujmebmpwk3"><img id="eu24z8ibtujmebmpwk3" src="https://cdn.durable.co/blocks/7aS9BPiZ7RQM41B9eruvOSOdRm02UJP7oPsqPfaBtFMsCa4Ai3zCGJdFoLy9GpuJ.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="Other Random Stuff I Built In College" data-positionx="undefined" data-positiony="undefined" data-fullwidth="false" data-mce-src="https://cdn.durable.co/blocks/7aS9BPiZ7RQM41B9eruvOSOdRm02UJP7oPsqPfaBtFMsCa4Ai3zCGJdFoLy9GpuJ.png" data-mce-style="aspect-ratio: 16/9; object-position: undefined undefined;"><figcaption class="body-normal text-gray-500 mt-2">Other Random Stuff I Built In College</figcaption></figure>

Liam Shanahan

Blog

E-Foil Surfboard

Autonomous Sailboat

ClearMotion

Electric Skateboard Build

CNC Manufacturing TA