Last Summer I...
Worked at the Arnold Engineering Development Complex (AEDC) Hypervelocity Wind Tunnel 9 in White Oak, MD. This is a unique, historic facility that has been at the forefront of hypersonic testing since the late 70's, and is capable of generating high Reynolds number flow at Mach 7-18 for run times not seen anywhere else in the country.
As an intern working in the aero-optical research lab, I was tasked with designing control system hardware and software to begin operation of a small adjustable nozzle Mach 5-7 pulsed wind tunnel for the purpose of cost-effective validation of non-intrusive optical diagnostics prior to implementation in Tunnel 9. I wrote extensive LabVIEW code to send trigger signals to fast-acting solenoid and poppet valves, implement safety interlocks, read and respond to pressure transducer data, and monitor other aspects of cyclic millisecond-long runs.
I also designed and built hardware to distribute power and my trigger signals to the fast-acting valves, set up N2 high-pressure piping & infrastructure, designed stands & mounts, planned and acquired materials for future pebble-bed heater integration, made all 3D CAD models + managed large assemblies for the entire system (pictures shown below), and designed an active nozzle modification to automate Mach number adjustments for future implementation.
Air Force HiFEX vehicle geometry readying for test at Tunnel 9. Novel airframe/engine integration combine with advanced test and evaluation techniques in a world-unique test environment to gain the very first data sets for this international US-German cooperative program as scientists and engineers look to the future of space access. (arnold.af.mil)
Full Assembly
Close-up of Active Nozzle Modification
Sectional View of Nozzle and Test Cell
Who am I?
I'm Zach, a Puerto Rican from Southern Maryland dedicated to creating and investigating innovative solutions in the mechanical engineering / aerospace field. I am driven by a desire to understand the universe, and to one day create cutting-edge solutions that push humanity forward.
A Look at My First Combat Robot:
Week-long Product Design Sprint
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How I keep busy
Hands-on design is what gets me up in the morning! Over the years, I’ve honed my skills with various CAD tools, 3D printing, manufacturing & assembly through diverse collaborative and individual projects. I thrive in dynamic team environments and strive to make informed design decisions. Sophomore year I co-developed a remote controlled hydrofoil kayak capable of levitating above the water, where I combined rigorous, grounded CAD design, machining, 3D printing, protective coatings, and power distribution to fabricate a reliable waterproof system.
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This semester, I am leading Duke's first-ever combat robotics hobbyweight-class (12lb) robot team after the succesful completion of our first beetleweight class last year, along with serving as President of the club. I don't just enjoy the technical side; I love leading teams to success and plan to manage 6-8 teams across mulitple weight classes. Last academic year I designed and helped manufacture the aerodynamic carbon fiber shell for Duke Electric Vehicle's 2025-26 urban concept car, along with custom door & lock mechanisms. I traveled with the team last spring to compete at the Shell Eco-Marathon at the Indie 500 track.
Back home in Southern Maryland, I enjoy exploring the Chesapeake Bay on kayak (although these ones don't fly) and by hiking, and have tackled team efforts to help restore the bay that I grew up to love. ​
While CAD and automatic sketches are convenient, I enjoy drawing by hand. Check out the gallery to see some of my recent work. My artistic side also comes in handy during most projects, as I am able to visualize my ideas and make blueprints, measurements, and exploded views right away. This strategy has consistently facilitated team organization and effective brainstorming.
Hydrofoil Kayak?!
BeetleWeight Combat Robot
Hand-Drawn Exploded View
Education
2019-2023
High School
St. Mary's Ryken
Where my passion for engineering began. While maintaining a 4.0 unweighted GPA, I was the Team Captain of both the Cross Country and Swimming teams. I also conducted extracurricular research with the nearby Patuxent River Naval Base. I kept busy with 3D printing and woodworking, and also entered drawings into local art galleries. I graduated from the PLTW engineering track, and finished my years here as valedictorian.
2023-present
Mechanical & Aerospace Engineering; Minor in Physics
Duke University
In studying here at Duke, I have refined my passion for engineering through involvement in clubs like Duke Aero (Structures), Combat Robotics (VP), Stargazing/Astronomy, Duke Electric Vehicles (Shell Design / Mechanical Team), and also through academic success utilizing the resources of the Pratt School of Engineering. Current Cumulative GPA: 3.9/4.0.