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Zachary Maldonado

Undergraduate Mechanical & Aerospace Engineering Senior at Duke University. Also an artist, runner, swimmer, space exploration enthusiast, learner, team player and leader, looking to make an impact on the world through engineering.

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During my Summer 2026 Internship 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 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 and building a control system 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 their 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 + trigger signals to the fast-acting valves, set up N2 high-pressure piping & infrastructure, designed stands & mounts, planned and acquired materials for heater integration, serviced the vacuum environment of the wind tunnel, made all 3D CAD models + managed large assemblies for the entire system. 

Towards the later months of my internship, I proposed a solution to transition the nozzle section from manual to automated Mach number adjustments compatible with my system in LabVIEW. I sized and chose actuators and other hardware based on thermal + load analysis and space constraints, designed a machinable mounting scheme, and managed a vacuum-compatible system.

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(the above image is of one of the nozzles for Tunnel 9, NOT the system I built)

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Who am I?

Astronomy enthusiast turned aspiring aerospace engineer driven by a desire to understand + explore the universe, and to create cutting-edge technology that allows humanity to do that. 

I thrive best in fast-paced, iterative design & testing environments where ambitious ownership on a team is balanced by system-level awareness. I have experience leading teams, and running design reviews on a professional level.

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Duke Combat Robotics

After serving as VP of DCR and building the club's first-ever 3lb combat robot, this year as President I am leading an initiative to expand again to 12 lbs (currently designing).​

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Additionally, I am leading/advising several other 1lb teams within the club, training members on technical skills, weapon physics, chassis structural design, material selection, manufacturing techniques, and electronic components + packaging. 

A Look at My First Combat Robot:

Technical Skills

3D Printing

3D CAD (e.g. SolidWorks); Large Assemblies

Composites

Electronic Packaging

Structures Design

Milling; CNC Milling

LabVIEW, Python, MATLAB

DAQ, Sensors &  Instrumentation

Mechanical System Integration

Wind Tunnel Testing

Nozzle Design

Material Selection

Design For Manufacturing

Education

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2023-present

Mechanical & Aerospace Engineering
Duke University

While studying at Duke, I have refined my passion for engineering through involvement in clubs like Duke Aero (Structures Team), Combat Robotics (President), Stargazing/Astronomy, Duke Electric Vehicles (Aerodynamics/Structures), and also through academic success utilizing the resources of the Pratt School of Engineering.

GPA: 3.93/4.00. 

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