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SYSTEM STATUS: ACTIVE PROTOTYPING & ENGINEERING

Mechanical Engineering
Built From The Ground Up

β€œI have been doing Mechanical Engineering my whole life.”

I’m a student who loves building, solving complex kinematic problems, and creating physical and virtual mechanisms that make life easier. My passion for machines started with hands-on physical assemblies and has evolved across real-time physics engines, digital twin simulations, CAD design in Fusion 360, and precision additive manufacturing.

70+ Piston Engines
14+ Escapement CADs
9,243 m/s Orbital Ξ”V
0.22mm FDM Air Gap
Explore Engineering Journey βš™οΈ Early Foundations aidenhockinberry@gmail.com
Aiden Hockinberry - Mechanical Engineering
Aiden Hockinberry
Mechanical Engineer & Systems Builder
● aidenhockinberry@gmail.com
DISCIPLINE:
01 // 3D PRINTING & MECHATRONICS

Fusion 360 Design & Additive Manufacturing

Transforming theoretical mechanics and digital simulations into physical realities. Leveraging Autodesk Fusion 360, TinkerCAD, and Creality 3D printers for high-precision component fabrication, tolerance testing, and functional electromechanical prototypes.

Fusion 360 CAD
Autodesk Fusion 360 Ergonomic Modeling Woodworking & Fabrication
Ergonomic Chair CAD
Table 3D CAD vs Real

Fusion Design: Parametric CAD & Physical Build

Applied parametric solid modeling in Autodesk Fusion 360 for complex product design. Engineered a multi-part ergonomic chair assembly and designed a dual-tone console table with cross-bracing that was fully translated from 3D CAD into a real-world physical build.

βš™οΈ Design Process
  • Parametric Constraining: Fully constrained sketches ensuring rapid dimensional modifications.
  • Joint Simulation: Verified mechanical interference and clearance fits prior to cutting materials.
πŸ”§ Manufacturing Fidelity
  • Achieved seamless 1-to-1 match between the virtual CAD render and the final physical wood-and-lacquer construction.
Fluid Dynamics & 3D Print
Autodesk TinkerCAD Creality 3D Printer Propeller Pitch Iteration Power Transfer Linkage
Wind Powered Kinematic Transport
Propeller Attempt 1
Propeller Attempt 2

Wind-Powered Kinematic Transport Prototype

Engineered a wind-driven rover that harnesses ambient air currents to generate forward mechanical locomotion. Developed custom multi-blade turbine propellers, evaluated fluid-dynamic pitch variations, and routed rotational energy to the drive axle through a 90-degree transmission linkage.

βš™οΈ Innovations
  • Optimized Blade Pitch: Iterated through several 3D-printed impeller geometries (Attempt 1 vs. Attempt 2) to maximize torque extraction at lower air velocities.
  • Power Transmission: Efficient bevel/gear linkage converting horizontal turbine rotation to vertical axle drive.
πŸ”§ Challenges Solved
  • Center of Gravity Management: Re-engineered the modular Technic chassis to prevent aerodynamic tipping under high frontal wind drag.
Precision Fastening Study
Tolerance: 0.22mm Ender 3 V3 KE Snap-Fit Cantilever PLA Material
Pocket Connect 4 Render
Exploded 3 Part View

Integrated Fastening Systems: The Pocket Connect 4 Study

Addressed the problem of component retention and portability in travel games by creating a compact, 3D-printed enclosure featuring an integrated cantilever snap-fit lid and friction-fit assembly base.

Component Mechanism Type Specification
Part 1: Cantilever Lid Snap-Top Flexure Joint Engineered deflection tooth with tactile lock
Part 2: Play Grid Column Alignment Core Precision slot guides with anti-jam chamfers
Part 3: Assembly Base Friction Fit Housing 0.22mm air gap tolerance on Creality Ender 3 V3 KE
Horological Kinematics & 3D Print
14 CAD Iterations 5-Stage Chain Drive 3-Gen Ratchet Physical Prototype Graveyard
Gravity Driven Escapement Apparatus
Escapement Graveyard
Chain & Ratchet Evolution

Gravity-Driven Escapement & Ratchet System

Designed and manufactured an entire gravity-powered pendulum clockwork mechanism. This comprehensive research study involved developing 14 discrete CAD iterations, 5 chain drive versions (from LEGO tread to custom modular 3D-printed link chains), and 3 ratchet generations to achieve continuous, deadbeat energy impulse transfer.

βš™οΈ Kinematic Sub-Assemblies
  • Escapement Wheel & Anchor: Optimized pallet tooth angle to minimize recoil and deliver consistent impulse to the pendulum bob.
  • Drive Train Evolution: Transitioned from LEGO treads (V1) to custom interlocking links (V5) for higher tensile strength without stretching.
πŸ”§ The Iteration Graveyard
  • Documented dozens of discarded prints to analyze tooth wear, friction coefficients, and center-distance tolerances in horological engineering.
Electromechanical Prototype
Hand-Wound Armature Lorentz Force Neodymium Array Commutator Timing
Brushed DC Motor Prototype

Brushed DC (BDC) Motor Prototype

Designed and assembled a functional brushed DC motor utilizing LEGO Technic for the structural chassis and a hand-wound copper wire armature. The project required micro-positioning of the commutator and brush system to ensure continuous current reversal and consistent torque generation.

βš™οΈ Electromechanical Highlights
  • Lorentz Force Rotor: Hand-wound magnetic coil armature situated inside a permanent magnetic field.
  • Stability Tower & Contacts: Spring-tensioned copper brush contacts aligned with commutator split rings.
πŸ”§ Challenges & Iterations
  • Flux Density: Swapped initial wiring for high-conductivity enamel magnet wire to increase coil density.
  • Field Calibration: Tested multiple neodymium magnet array configurations to maximize RPM without stalling.
02 // THE VIRTUAL ERA

Engineering Beyond Physical Constraints & Digital Twins

Transitioning from physical parts to high-fidelity physics engines (Kerbal Space Program, Scrap Mechanic, modded Minecraft). Using virtual sandboxes as real-time dynamic CAD testbeds to validate kinematics, orbital trajectory staging, and multi-axis logic loops prior to physical fabrication.

Virtual Prototyping
70+ Engine Builds Torque Optimization Crankshaft Balancing Timing Cam Tuning

Click any engine block to inspect in high-resolution CAD lightbox (27 detailed variants shown).

Virtual Prototyping: 70+ Piston Engine Iterations

Utilized real-time physics engines as a dynamic mechanical testing sandbox to design, construct, and stress-test over 70 custom piston engine configurations. Iterated across inline, radial, V-type, and boxer layouts to maximize torque output, optimize ignition timing efficiency, and eliminate crankshaft torsional resonance.

βš™οΈ Engineering Focus
  • Crankshaft Phase Shifts: Calibrating offset throw angles to maintain continuous power delivery and reduce vibration harmonics.
  • Valve & Timing Sequences: Engineering intake/exhaust phase timing to maximize stroke displacement and cylinder volumetric efficiency.
πŸ”§ Simulation As Rapid Prototyping
  • Identified structural fatigue points and bearing stress tolerances in milliseconds without material fabrication waste, mirroring industry Digital Twin workflows.
Virtual Automotive CAD
Piston Drivetrain Double Wishbone Suspension Universal Joints
Mechanical Automotive Design CAD

Mechanical Automotive Chassis & Drivetrain

Engineered a complete vehicle chassis integrating a central custom piston engine, independent suspension linkages, and universal joint drive shafts. Designed to test torque transfer during uneven terrain deflection.

βš™οΈ Sub-System Architecture
  • Universal Joint Transmission: Accommodates angular displacement between the differential and wheel hubs under suspension travel.
  • Independent Damped Suspension: Geometry optimized to minimize body roll and keep tires planted.
πŸ”§ Kinematic Analysis
  • Validated steering knuckle kingpin inclination and Ackerman steering geometry under dynamic wheel turn loads.
Aerospace & Orbital Case Study
Kerbal Space Program 5-Stage Rocket Ξ”V Budget: 9,243 m/s Orbital Staging
Rocket Staging Simulation
Stage 1: High TWR Atmospheric Escape (SRBs)
High thrust-to-weight solid rocket boosters engineered to overcome sea-level atmospheric drag and punch through the thick lower atmosphere with maximum initial impulse.

Case Study: Simulated Mun Mission Architecture

Designed a complete 5-stage spacecraft architecture engineered for orbital insertion, trans-lunar transfer, surface touchdown, and atmospheric reentry recovery. Calculated delta-V requirements using the Tsiolkovsky rocket equation to ensure mission feasibility.

Mission Metric Specification Engineering Purpose
Total Mission Ξ”V 9,243 m/s Sufficient for LKO, TMI, capture, landing, ascent, & return
Vehicle Part Count 147 Components Optimized for structural integrity & aerodynamic fairing limits
Staging Architecture 5 Discrete Stages Maximizes vacuum specific impulse ($I_{sp}$) by discarding dry mass
Ascent Profile Gravity Turn @ 70km Gradual pitch-over to trade vertical climb for horizontal orbital velocity
Landing Dynamics Wide-Stance Quad Legs Prevents tipping on uneven regolith during constant-altitude suicide burns
Robotics & Mechatronics
Biomimetic Linkages Boolean Logic Gates Gait Timing Optimization Arduino-Style Sequencing
Biomimetic Robot
Digital Logic Gates

Biomimetic Robotics & Logic-Driven Kinematics

Designed a multi-legged walking mechanism integrating sequential rotation matrices and an on-board digital logic array to coordinate joint phase shifts. This mechatronic system synchronizes mechanical linkages to translate rotary motion into a stable linear gait while optimizing runtime timing to prevent joint binding.

βš™οΈ Digital Logic Architecture
  • Boolean Gate Matrix: Configured standard logic gates (AND, OR, XOR, NAND) to handle state machines and control feedback loops.
  • Phase Shifting: Prevents opposing leg pairs from entering identical stride phases simultaneously.
πŸ”§ Sequential Multi-Axis Actuation
  • Functions exactly like a real-world programmable microcontroller (e.g. Arduino) to time specific rotational angles of hip and knee joints during walking cycles.
03 // PHYSICAL FOUNDATIONS

Physical Prototyping & Kinematic Foundations

Hands-on tactile exploration in gear ratios, structural rigidity, torque balance, and dynamic equilibrium. Building functional proof-of-concept machines from raw structural components.

Early Era Prototype
Synchronized Motors Belt Drive Load Balancing Technic Chassis
Linear Transport System Prototype

Linear Transport System Prototype

Designed a heavy-duty linear transport carriage utilizing a dual-motor synchronized drive to balance load distribution across track guide beams. Focused on structural rigidity during high-cycle dynamic reversals.

βš™οΈ Key Technical Features
  • Dual Motor Drive System: Synchronized high-torque motors for balanced power distribution and reduced belt slippage.
  • Reinforced Chassis Design: Robust Technic beam structure designed to minimize vibration during high-cycle load reversals.
πŸ”§ Challenges & Solutions
  • Challenge: Initial belt tension issues causing dynamic instability and tooth jumping.
  • Solution: Iterated pulley and track configurations to optimize traction and alignment under varying loads.
  • Inertia Management: Implemented structural cross-bracing and a tuned gear-train to absorb kinetic energy.
Early Era Prototype
Mechanical Linkages Rotary-to-Linear Gear Trains
Mechanical Logic Exploration

Mechanical Logic & Linkage Exploration

Investigating spatial motion translation and mechanical timing through interconnected gear linkages. These foundational hands-on builds established intuition for gear backlash, mechanical advantage, and non-binding pivot kinematics.

βš™οΈ Core Principles
  • Motion Conversion: Transforming continuous rotational inputs into reciprocating mechanical output strokes.
  • Friction Mitigation: Pin tolerance alignment and reduction of multi-pivot parasitic drag.
πŸ”§ Engineering Takeaways
  • Developed an early hands-on sense of tolerance budgeting and physical constraints that later drove high-precision CAD modeling.
Early Era Prototype
Rotational Inertia Dynamic Symmetry Wireframe CAD
Dynamic Rolling Structure Physical
Dynamic Rolling Structure CAD

Self-Stabilizing Dynamic Rolling Structure

Conceived and engineered a large-scale self-stabilizing rolling ring structure. By distributing radial structural truss members symmetrically around a central hub, the mechanism maintains rotational momentum and self-rights under dynamic perturbation.

βš™οΈ Structural Dynamics
  • Radial Truss Geometry: Multi-point radial spoke network providing high torsional stiffness against lateral roll forces.
  • Gyroscopic Tendency: Perimeter mass concentration maximizing moment of inertia ($I = m r^2$).
πŸ”§ Digital-Physical Bridge
  • Modeled in 3D wireframe space to verify angular symmetry before physical assembly with modular structural struts.
04 // COMPETENCIES

Engineering Skills & Toolchain

Interdisciplinary capabilities spanning computer-aided design, additive prototyping, electromechanical assembly, digital twin simulations, and kinematic optimization.

πŸ“

CAD & Modeling

Autodesk Fusion 360 TinkerCAD Parametric Modeling Assembly Mates & Joints Tolerance Analysis (0.22mm) Wireframe Modeling Exploded Assembly Views
πŸ–¨οΈ

Additive & Fabrication

Creality Ender 3 V3 KE FDM Slicing & Cura PLA & Composite Materials Cantilever Snap-Fits Friction-Fit Assemblies Woodworking & Joinery Makerspace Machine Tools
βš™οΈ

Kinematics & Mechatronics

Escapements & Clockwork Ratchet & Pawl Drivetrains Gear Trains & Backlash Brushed DC Motor Design Armature Winding Universal Joint Mechanics Multi-Axis Actuation
🌌

Virtual Simulation

Digital Twin Workflows Kerbal Space Program (KSP) Scrap Mechanic Physics 70+ Piston Engine Designs TWR & Ξ”V Optimization Orbital Staging Profiles Gravity Turn Mechanics
⚑

Logic & State Control

Boolean Logic (AND, OR, XOR) State Machine Architecture Sequential Micro-Timing Strandbeest Walking Gait Sensor Feedback Loops Geyser/PaperMC Automation
πŸ”¬

Engineering Methods

Failure Point Identification Rapid Iterative Prototyping Requirement Analysis Center of Gravity Tuning Fluid Dynamics (Propeller Pitch) Inertia & Momentum Balance
05 // GET IN TOUCH

Let’s Build Something Remarkable

Whether you’re interested in collaborating on mechanical engineering projects, discussing prototype design, or exploring engineering opportunities, feel free to reach out directly.

βœ‰οΈ
Email
aidenhockinberry@gmail.com