ListerAerospace

Portfolio

A sample of work across analysis, design, tooling, and manufacturing.

Details generalized where projects are proprietary. Models shown are simplified or de-featured, with select geometry omitted.

Representative de-featured model illustrating sheet-metal baffle geometry and manufacturing complexity.
  • Design
  • Manufacturing

Engine Baffle Manufacturing Automation

Modernized legacy, paper-driven engine baffle production into a semi-automated CNC workflow, replacing manual cutting with controlled digital manufacturing data to improve repeatability and throughput.

Abstracted airframe configuration illustrating nose-gear integration and landing-gear layout.
  • Design
  • Analysis
  • Certification

Nose Gear Conversion & Airframe Reconfiguration

Led the airframe and landing-gear reconfiguration from a tailwheel platform to a nose-gear variant, covering structural integration, prototype development, and validation planning through drop testing.

Representative die-set assembly illustrating punch, die, and part-locating features.
  • Tooling
  • Manufacturing

Production Tooling & CNC Tube Fabrication

Designed production bending dies for formed sheet-metal brackets and gussets, and built a digital tube-fabrication workflow on a CNC tube bender that replaced manual layout and hand-fitting.

Aerodynamic speed fairing modeled on a landing-gear leg, shown installed within the surrounding airframe.
  • Design
  • Surfacing

Aerodynamic Fairing Design

Modeled the exterior surface of an aerodynamic speed fairing for a landing-gear leg, shaping a smooth, low-drag form and integrating it with the surrounding airframe structure.

Throttle quadrant cover housing, showing the control-lever slot geometry.
  • Design
  • Surfacing

Throttle Quadrant Cover Design

Designed the cosmetic cover housing for a throttle control quadrant, shaping an ergonomic, low-profile surface around the control-lever slots.

Flap quadrant cover housing, showing the control-lever slot geometry.
  • Design
  • Surfacing

Flap Quadrant Cover Design

Designed the cosmetic cover housing for a flap control quadrant, shaping a smooth exterior surface around the lever slot and mounting interface.

Welded engine mount ring showing coped tube intersections at each joint.
  • Design
  • Manufacturing

Engine Mount Ring & Tube Coping

Modeled a welded engine mount ring with multiple coped tube intersections, defining joint geometry to support fixturing and weld fit-up.

Proprietary details omitted
  • Certification
  • Test

Tailwheel Redesign & FAA Drop Test Validation

Led integration and validation of a redesigned tailwheel system through FAA-observed drop testing, working directly with an FAA representative to separate transient test noise from true structural response.

Proprietary details omitted
  • Design
  • Process

Legacy Engineering Data Modernization

Converted a paper-based drawing and configuration-control system into a structured digital dataset, cutting drawing-list update time from days to minutes and strengthening traceability.

Additional projects and references available on request.

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