I'm an Innovation and Simulation Manager working at the intersection of engineering, data, and real-world application. My background is in mechatronics, but over 20+ years I've built a career around solving complex, multidisciplinary problems that sit somewhere between physics, software, and commercial reality.
I've worked across aerospace, petrochemical, and commercial vehicle sectors. Today I lead innovation for truck-mounted sweepers at Bucher Municipal - developing intelligent, data-driven systems from what were traditionally purely mechanical products.
Engineered By Design started in 2006 as a place to document real work alongside the sprint car programme. The tools, calculators, and reference data on this site all came from genuine project needs - built because they were needed, published because others would find them useful.
Professional Work
My current focus is on transforming traditional mechanical products into intelligent, data-driven systems. At Bucher Municipal I lead the development of SmartAssist - an AI-driven platform that automates sweeping functions, reduces operator workload, and redefines how street cleanliness is measured and delivered.
Alongside that, I'm pushing simulation-led engineering using coupled DEM-CFD models, Physics AI, and reduced-order modelling to bring virtual validation into everyday engineering decisions. I operate across both technical and strategic layers - whether that's working through CAN data and control systems, shaping product direction, or aligning engineering with commercial outcomes.
I've been named on 9 patents covering airflow optimisation, control systems, and vehicle dynamics, with 2 academic papers to my name. I'm currently sponsoring a PhD focused on advancing simulation capability for complex particle-fluid interactions.
AI and Simulation
Physics AI, DEM-CFD coupled simulation, reduced-order modelling. Bringing virtual validation into real engineering workflows.
Patents and Research
9 patents across airflow optimisation, control systems and vehicle dynamics. 2 academic papers. Active PhD sponsorship in particle-fluid simulation.
CAD and Consultancy
Design, analysis, and development across automotive and aerospace applications. Concept through to production-ready solutions.
Motorsport
Motorsport has been a constant thread throughout my engineering career - not just as a hobby, but as a practical extension of how I approach problems. The direct feedback loop is the point: engineering decisions play out immediately, and there's nowhere to hide when something doesn't work.
I currently work with SupaTune Motorsport in the Porsche Club GB championships, supporting both the Boxster Cup and AM/Class 1 series. In 2026 we're running 9 cars across the two championships.
Boxster Cup – 2026
Adam Warner
Region R25 – Kent
Tony Jones
Region R10 – Milton Keynes & Northamptonshire
Brenden Haffner
Region R13 – Hereford, Worcestershire & Shropshire
Stuart Warner
Region R25 – Kent
Tony Levy
Region R29 – Surrey
Adam Spencer
Region R25 – Kent
AM / Class 1 – 2026
Faye Noble-Evans
Region R29 – Surrey
Pete Evans
Region R29 – Surrey
Perry Darling
Championship placement to be confirmed.
I work extensively with the AiM EVO4S and Motorsport VBOX Video HD2 for data capture and analysis - GPS positioning, vehicle dynamics channels, and synchronised video. That feeds a continuous cycle of post-session analysis, setup refinement, and driver coaching. Being involved at both mechanical and data levels means I'm part of the full system: setup, diagnostics, performance analysis, and race strategy.
The Sprint Car Roots
Before Porsche Club GB, EBD Racing ran an active sprint car programme from 2006 through multiple classes and chassis. Each car was built and developed in-house - not bought and bolted. The PPP-106 Peugeot 106 Rallye was the original, and it's still the subject of the most detailed engineering study on this site.
One standout project from that era was a single-cylinder speedway racing engine producing approximately 63 BHP - the equivalent of 250 BHP per litre normally aspirated, weighing under 30 kilograms complete. That kind of constraint-led development - extract maximum performance from minimum weight - is still how I think about engineering problems.
Peugeot 106 Rallye
1400cc naturally aspirated. The original EBD sprint car, extensively developed over multiple seasons.
Vauxhall Nova
A-series powered hillclimb and sprint car. Lightweight shell, big cam, twin 40 DCOEs.
Nova Twin Cam
Modified production class. Twin 40 DCOE carburettors. TWMC and RMC sprint series.
Ford Fiesta
1400cc Ford-based sprint car. FF class competitor.
Ford Focus ST170
2.0 Duratec development platform. Performance development and data logging.
Godden Engine
Single-cylinder racing engine. ~63 BHP, under 30 kg. The constraint-led project that still shapes how I think about engineering.
Approach
Across professional work and motorsport, the same principles apply. Engineering has to work in the real world, not just in theory. Data is powerful, but only if you understand its context and limitations. Small improvements, applied consistently, create meaningful change. The best solutions sit at the intersection of disciplines, not within silos.
I'm interested in where engineering is heading. AI, data ownership, and regulatory shifts like the EU Data Act are starting to reshape industries. A lot of time goes into thinking about how to position technology and organisations ahead of that curve rather than reacting to it.
If there's a common thread: build things that work in the real world, then scale them into something that delivers measurable value.