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SYSTEM STATUS: ACTIVE PROTOTYPING & ENGINEERING

Mechanical Engineering
Built From The Ground Up

“I 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
6-Axis Mechatronics
15 Engineered Systems
👤 About Aiden & Resume → Explore Engineering Builds 📄 Official Resume
Aiden Hockinberry - Mechanical Engineering
Aiden Hockinberry
Mechanical Engineer & Systems Builder
SELECTED ENGINEERING BUILDS & CASE STUDIES

Functional Machines, Kinematics & Digital Twins

15 functional machines, robotic systems, fluid turbomachinery, and digital twin simulations—engineered, prototyped, and validated from first principles.

Horological Kinematics & 3D Print
🔄 14 CAD Iterations 5-Stage Chain Drive 3-Gen Ratchet Physical Prototype Graveyard 🎬 Physical Test Video
Gravity Driven Escapement Apparatus
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🧊 Cylinder Escapement Wheel 9,872 Triangles • .STL
Rendering 3D Escapement Wheel... Autodesk Fusion 360 • 493 KB
Autodesk Fusion 360 CAD Axes: X/Y/Z • Centered Origin
🖱️ Rotate: Left-drag • Zoom: Scroll • Pan: Right-drag • Center: Double-click or '🎯 Reset'
⬇️ Download .STL (493 KB)

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.

⚙️ 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.
🔧 The Iteration Graveyard
  • Documented dozens of discarded prints to analyze tooth wear, friction coefficients, and center-distance tolerances in horological engineering.
🔄 Escapement Mechanism Iterations 🔍 Click to Expand Page
Gravity-Driven Escapement 14 CAD Iterations Portfolio Page (Page 16)
⛓️ Drive Train & Ratchet Iterations 🔍 Click to Expand Page
Gravity-Driven Pendulum Ratchet & Drive Train Evolution Portfolio Page (Page 18)
Virtual Prototyping & Digital Twin
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.

⚙️ 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.
🔧 Simulation As Rapid Prototyping
  • Identified structural fatigue points and bearing stress tolerances in milliseconds without material fabrication waste, mirroring industry Digital Twin workflows.
Aerospace & Orbital Case Study
Kerbal Space Program 5-Stage Rocket ΔV Budget: 9,243 m/s Orbital Staging Tsiolkovsky Optimization
Rocket Staging Simulation
Stage 1: Launch Pad Ignition & SRB Atmospheric Boost
Phase 1: Lift-Off | TWR > 1.8
Solid Rocket Boosters (SRBs) ignite alongside the center liquid core to punch through Kerbin’s dense lower atmosphere with massive sea-level thrust and high initial impulse. Telemetry HUD: Altitude 374m, Stage 005, Total Mission ΔV 9,243 m/s.
5-Stage Rocket Blueprint Schematic
1
Ascent Stage (Twin SRBs): High-thrust solid rocket motors delivering TWR > 1.8 to overcome initial atmospheric drag.
2
Booster Core: High-capacity central liquid propellant sustainer executing pitch-over gravity turn into 70km parking orbit.
3
Trans-Munar Injection (TMI) Stage: Vacuum-optimized engine maximizing specific impulse ($I_{sp}$) for translunar Hohmann transfer.
4
Munar Descent & Ascent Stage (Lander): Throttleable descent module with wide-stance quad landing legs & separable ascent stage.
5
Command Module & Recovery: Aerodynamic capsule with blunt heat shield and sequenced triple recovery parachutes.

Case Study: Simulated Mun Mission Architecture

Designed and simulated a complete 5-stage spacecraft architecture in Kerbal Space Program (KSP), 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 across all flight regimes.

Total Mission ΔV 9,243 m/s Sufficient for LKO, TMI, capture, landing, ascent & return
Vehicle Part Count 147 Parts Optimized for structural integrity & fairing volume
Staging Architecture 5 Discrete Stages Maximizes vacuum specific impulse ($I_{sp}$)
🚀 Section 1: Design Philosophy & Multistage Integration (Page 8)
  • Staging Strategy (Maximizing Vacuum $I_{sp}$): Discarding dead structural mass (empty fuel tanks and spent booster casings) drastically increases the vehicle mass ratio ($m_0 / m_f$). Initial ascent utilizes high sea-level thrust solid and liquid boosters (TWR > 1.8), transitioning to high vacuum specific impulse engines ($I_{sp} > 350\text{s}$) for trans-munar burns.
  • Gravity Turn Optimization: Executed a continuous aerodynamic pitch-over maneuver through Kerbin's 70km atmosphere. Locking vehicle thrust to the surface prograde vector minimizes cosine steering losses and atmospheric drag while converting vertical impulse into horizontal orbital velocity.
🌕 Section 2: Landing Dynamics & Surface Operations (Page 9)
  • Wide-Stance Quad Landing Gear: Low center-of-gravity quad footprint resists tip-over moments on sloped lunar crater walls up to 15° inclination. Telescopic oleo struts with integrated damping absorb touchdown impact without elastic rebound.
  • Deceleration Profile ("Suicide Burn"): Precision throttle governance zeroes out horizontal and vertical velocities simultaneously meters above the surface, eliminating fuel-costly hover phases and minimizing gravity drag.
🪂 Section 3: Ascent & Re-Entry
  • Ascent Staging: Descent stage serves as a stationary launch base; decoupling the upper ascent capsule sheds dead structural mass for the return trip.
  • Parachute Recovery: Blunt heat shield dissipates >3,200 m/s entry velocity, followed by staged triple parachutes slowing the capsule to <6 m/s.
🔬 Systems Evaluation & Takeaway
  • Real-World Aerospace Validation: Demonstrates that real-time physics environments function as valid Digital Twins to verify multi-variable trade-offs in aerospace staging logic before costly hardware fabrication.
Robotics & Mechatronics
Biomimetic Linkages Boolean Logic Gates Gait Timing Optimization Arduino-Style Sequencing
Final Biomimetic Walking Robot
Rotation Sequencer
Logic Gates
🔄 Prototyping Evolution (V1 → V3) Click to inspect engineering iteration in full HD
Iteration 1 Structural Spine
Iteration 1: Structural Spine Bare chassis, damper mounts & leg stations
Iteration 2 Elongated Spine
Iteration 2: Elongated Spine Multi-segment chassis, cockpit & test stand
Iteration 3 Enclosure Shell
Iteration 3: Enclosure Shell Protective hull & elevated leg clearance
⚡ Gait "Coding" & Logic Configuration Click to inspect sequencer & state-machine
Rotation Editor Sequencer
Level 5 Rotation Sequencer Sequential angular phase timing (+90° step loops)
Boolean Logic Gate Configurator
Boolean Logic State Machine AND, OR, XOR, NAND gate phase coordination

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.

⚙️ 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.
🔧 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.
Fluid Dynamics & Kinematics
🌪️ Headwind Propulsion Multi-Blade Turbine 90° Bevel Gearbox Spur Reduction Stage Universal Joint Linkage
🌪️ LIVE TEST: HEADWIND TRAVERSAL (15s)
Wind-Powered Kinematic Transport Prototype
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Lower Drivetrain Gear Mesh
Bevel Gear Transmission
Universal Joint Linkage
⚙️ Mechanical Power Transmission Architecture Click any technical component to inspect in full HD
Lower Drivetrain Assembly
Bevel Gear Box
Universal Joint
🌪️ Aerodynamic Impeller Design & Pitch Iterations 3D CAD modeling in TinkerCAD with fluid dynamic pitch tuning
Propeller Attempt 1
Propeller Attempt 2
Physical Turbine Rotor

Wind-Powered Kinematic Transport Prototype

Conceived, modeled, and physically built an autonomous wind-propelled rover capable of crawling directly into headwind airflow. Harnessing wind currents with a custom 3D-printed multi-blade turbine impeller, the rover routes rotational kinetic energy through a multi-stage transmission: a lower spur gear reduction to drive the front wheels, an angled universal joint linkage, and a top 90-degree bevel gearbox driving dual crank arms. Validated on a dedicated test bench against an electric fan airflow, proving sustainable forward mechanical propulsion against aerodynamic resistance.

⚙️ Fluid Dynamics & Impeller Synthesis
  • Aerodynamic Pitch Optimization: Iterated through multiple 3D-printed blade angles in TinkerCAD, evaluating 0° flat vs. 45° helical pitch to minimize startup stall speed and extract maximum rotational torque.
  • Multi-Blade Rotor Dynamics: High-solidity blade layout captures low-velocity airflow efficiently, generating sufficient starting torque to overcome static chassis inertia and rolling resistance.
🔧 Mechanical Drivetrain & Kinematics
  • Multi-Stage Gear Reduction: Meshed spur gear stage inside a Technic cage steps up mechanical torque from the high-RPM turbine shaft to the front drive axle.
  • 90° Bevel Gearbox & U-Joint: Angled universal joint transfers rotational power up to a top bevel gear stage driving dual counter-phased crank arms.
  • Kinematic Drag Struts: Trailing support struts provide 3-point static stability, preventing aerodynamic pitch-back under high frontal wind drag.
Electromechanical Prototype
Hand-Wound Armature Lorentz Force Neodymium Array Commutator Timing 🎬 Physical Test Video
Brushed DC Motor Prototype
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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.

⚙️ 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.
🔧 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.
Virtual Automotive CAD
Piston Drivetrain Double Wishbone Suspension Universal Joints
Mechanical Automotive Chassis CAD - Front View

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.

⚙️ 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.
🔧 Kinematic Analysis
  • Validated steering knuckle kingpin inclination and Ackerman steering geometry under dynamic wheel turn loads.
Rotational Inertia Prototype
Rotational Inertia Dynamic Symmetry Kinetic Truss Ring Pendulum Drive Hub
Dynamic Rolling Structure - Full Physical Build
Dynamic Rolling Structure - Hallway Stability Test
Dynamic Rolling Structure - Radial Truss Assembly
Dynamic Rolling Structure - Internal Motorized Core

Environmental-Stabilizing Dynamic Rolling Structure

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

⚙️ 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 ($I = m r^2$).
🔧 Internal Drive & Stabilization
  • Suspended Core Module: Integrated an internal motorized pendulum hub suspended within the ring core, lowering the center of gravity and providing active drive thrust.
  • Dynamic Hallway Testing: Physically tested forward roll momentum and angular equilibrium to validate upright self-stabilization.
Fastening & Iterative Prototyping
🔄 5 Iteration Cycles Tolerance: 0.22mm Creality Ender 3 V3 KE Compliant Cantilever Flexure PLA Material
Pocket Connect 4 Render
Exploded 3 Part View
Pocket Connect 4 Iteration Evolution
🔍 Expand

Integrated Fastening Systems: The Pocket Connect 4 Design Study

Addressed the lack of portability and component retention in traditional tabletop games by engineering a compact, 3D-printed enclosure. The study centered on the systematic design, stress analysis, and empirical testing of an integrated compliant cantilever snap-fit lid and friction-fit assembly base.

Component Mechanism Type Engineering Specification
Part 1: Cantilever Lid Snap-Top Flexure Joint Calibrated flexure arm with tactile positive detent retention
Part 2: Play Grid Column Alignment Core Internal gravity-drop token channels with anti-jam chamfers
Part 3: Assembly Base Friction Fit Housing 0.22mm calibrated air gap tolerance on Ender 3 V3 KE
Fusion 360 CAD
Autodesk Fusion 360 Parametric Solid Modeling Multi-Body Assemblies Observational CAD Studies
🪵 Console End Table
AUTODESK FUSION 360 STUDIES
💺 Ergonomic Chair
Console End Table 3D CAD Model - Autodesk Fusion 360 🪵 Console Table
Ergonomic Chair 3D CAD Model - Autodesk Fusion 360 💺 Ergonomic Chair
Autodesk Fusion 360: Click either study to inspect the high-resolution CAD solid model in full detail

Fusion 360 Design: Observational CAD Studies

Applied advanced 3D solid modeling in Autodesk Fusion 360 to execute observational CAD reverse-engineering studies of complex everyday objects. Inspired by real-world physical furniture, these digital studies focus strictly on CAD craftsmanship and parametric technique: reconstructing complex physical geometry from visual observation into fully constrained 2D sketches, organic ergonomic contours, and multi-body solid assemblies without relying on external blueprints. Featured models include a multi-component ergonomic chair assembly with contoured lumbar support and 5-point caster base, alongside a craftsman-style console end table featuring angled truss cross-bracing and a lower slatted shelf.

⚙️ Parametric CAD Architecture
  • Fully Constrained Sketching: Recreated observed proportions using parametric 2D profiles with geometric constraints (tangency, symmetry, perpendicularity) for dynamic dimension scalability.
  • Multi-Body Assemblies: Structured complex assemblies into distinct components (swivel star base, gas cylinder, contoured backrest, armrest brackets, table cross-braces, and slatted shelf).
📐 Observational Reverse-Engineering
  • Ergonomic Curvature & Proportion: Modeled compound curves, lumbar fillets, and frame structural ratios purely from visual observation, achieving high dimensional harmony.
  • Material Finish & Rendering: Applied physical appearance materials (wood grain textures, matte and gloss polymers, and metallic finishes) with custom environment lighting in Fusion 360's render workspace.
04 // COMPETENCIES

Engineering Skills & Toolchain

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

📐

CAD & Modeling

Autodesk Fusion 360 TinkerCAD Parametric Modeling Assembly Mates & Joints Tolerance Analysis (0.22mm) Wireframe Modeling Exploded Assembly Views
🖨️

Additive & Fabrication

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

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 & ΔV Optimization Orbital Staging Profiles Gravity Turn Mechanics
⚡

Logic & State Control

Boolean Logic (AND, OR, XOR) State Machine Architecture Sequential Micro-Timing Hexapod Dynamic Walking Gait Sensor Feedback Loops Geyser/PaperMC Automation
🔬

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.

✉️
Email
aidenhockinberry@gmail.com