QUALIFICATIONS

BE Mech (Hons) – 2015

SOFTWARE

Mechanical CAD Software

Creo (PTC)
Fusion (Autodesk)
Inventor (Autodesk)
OnShape (PTC)
SolidWorks (Dassault)

Architectural / Structure CAD Software

SAP2000

PDM/PLM Software

Inventor Vault (Autodesk)

Analysis Tools

ANSYS Fluent
ANSYS Mechanical
ANSYS Workbench
Excel (for numerical method analysis)
Mecway FEA
SolidWorks Flow
SolidWorks Simulation
Visual Analysis

Aaron Johnson

ANALYSIS LEAD

Skills Overview

Aaron is an experienced mechanical engineer with a background in high-performance automotive, marine prototypes, and energy storage systems. He quickly grasps the fundamental requirements of any project, ensuring efforts are focused on the most valuable aspects. Aaron’s broad experience and interests allow him to bring innovative solutions by cross-fertilizing ideas from various disciplines. He has extensive hands-on design and leadership experience across industries, and is skilled in product development, project management, and leading multidisciplinary teams.

PROTOTYPE / PRODUCT DEVELOPMENT – Aaron’s background in prototype development and early stage companies mean that he is adept at delving to the core of what a prototype or product must achieve for success and how best to quickly design, test, and develop products.
MACHINE DESIGN – With significant experience in machine design Aaron can design machines and components for most manufacture processes (3, 4 & 5 axis CNC machining, sheet metal, 3D printing, short-run casting, fabrication, and composites). He brings a strong focus on getting the fundamental concepts right to reduce loop backs later in the design process.
ANALYSIS & CALCULATION – Aaron has strong analytical skills, with experience ranging from FEA-based mechanical analysis to dynamic numerical simulations, mathematical modelling, and even process modelling. He has a good understanding of the advantages and disadvantages of various types of analysis and when they should (and shouldn’t) be used. Further to this he has a strong foundation in engineering calculations, both from first principles and to national and international standards.
PROJECT ENGINEERING & TEAM LEADERSHIP – Aaron has extensive experience leading multidisciplinary teams and managing complex projects across various industries, including hydrogen technology and autonomous systems. He has guided projects from concept through to completion, ensuring alignment between technical and commercial goals. With a focus on delivering innovative solutions, Aaron excels in client interfacing, managing stakeholder relationships, and mentoring junior engineers. His leadership ensures successful collaboration within teams while driving projects to meet timelines and deliver high-quality results.
FABRICATION, ASSEMBLY, AND TESTING – Aaron has a strong hands-on background in fabrication, assembly, and testing of mechanical systems. He has worked extensively on building prototypes, from designing and assembling vehicle components to constructing and testing complex test rigs. His practical experience includes electrical system installations, precision mechanical maintenance, and troubleshooting in both workshop and field environments. Aaron’s ability to combine theoretical knowledge with practical application ensures that his designs are optimised for real-world performance and manufacturability.

Caliber has experience in the Agriculture industry

Caliber Design has experience in the Biofuel industry

Caliber has experience in the Aerospace industry

PERSONAL STATEMENT

I enjoy engineering because I have a passion for solving problems. Like many at Caliber, this emerged when I was very young. I had a fascination with pulling things apart to figure out how they worked and how they could be repaired or improved (over time I even graduated into putting things back together again). I have a particular interest in technology that helps to move us towards a more sustainable society.

Project Experience

BASIS

Test Rig Design & Build

Designed and built a custom test rig for a Basis. The rig was used to test one of their advanced sensors, requiring precise mechanical control to simulate electrical conditions. I refined the design brief, developed a variety of concepts, completed detailed design and drawings, oversaw part sourcing, and coordinated with manufacturers. I assembled, tested, and commissioned the rig, ensuring it met the technical and functional requirements of the client.

Conveyor Design

Contributed to the design and development of industrial conveyor systems for a quarry site for Mimico. I was responsible for detailed CAD drafting, ensuring proper interfacing and guarding for the conveyors, and working closely with the team to finalise designs that optimized performance and safety in heavy industrial environments.

FORMULA SAE / FORMULA STUDENT

Initially drafted into the powertrain team, I later became the leader of the powertrain team, suspension team, race engineer, and was the chief engineer in 2014. I led the design and development of the vehicle’s suspension and vehicle dynamics systems, focusing on optimizing performance and handling. My leadership played a key role in driving the team through multiple vehicle iterations, ensuring the car’s reliability and competitiveness during track testing and competitions, culminating in 3^rd place overall in the 2014 Australasian competition, the teams best finish at that point.

FABRUM

Liquid Hydrogen Project

Worked as a project engineer on a large liquid hydrogen project for Fabrum. He initially focused on the design of pressure vessels and hydrogen storage tanks but quickly expanded to overseeing the storage and distribution systems and managing relationships with end users. Aaron managed multidisciplinary teams, collaborated with external consultants and external stakeholders, and played a key role in safety and risk assessments (HAZOPs, HAZIDs). My contributions ensured the successful integration of mechanical systems while meeting strict safety and performance standards.

GIBBS AMPHIBIANS

Biski Project

Across the various projects undertaken while at Gibbs, I had a hand in designing almost every vehicle subsystem. For example, during the design and development of the Biski (a high-speed amphibious motorcycle), my responsibilities covered designs for the front and rear suspension systems, including retraction mechanisms, steering systems, jet pumps, intake and exhaust systems, and engine cooling. I managed the entire design cycle, from initial concepts to manufacture, assembly, testing and refinement, ensuring the vehicle met both performance and reliability requirements in marine environments.

MEDICAL DEVICE STARTUP

I worked with a medical device startup, tasked with reworking the CAD model for initial testing of a prototype. He provided key insights into design for manufacturability, tooling, and prototype development. My contributions helped refine the design and prepare it for manufacturing.

AGOVOR

Autonomous Tractor

I worked with Agovor, an early-stage startup, on the design and prototyping of autonomous tractors. Contributed to refining existing designs, developing new mechanical components, and providing insights for future iterations. My contribution played a critical role in advancing the company’s autonomous vehicle technology through early-stage prototype development and testing. CASE STUDY

VAN CONVERSION PROJECT

Undertook the design and build of a custom camper van, transforming it into a fully functional living space for two years of travel. This work included the design and installation of the van’s solar and electrical systems, lighting, and water systems (fresh and grey water). I was also responsible for the layout and fit-out design, as well as mechanical maintenance, including a full engine rebuild and significant bodywork repairs. This project combined practical engineering with design, providing valuable hands-on experience across multiple systems.

ENERGY STORAGE STARTUP

As a co-founder of an energy storage startup, I led the mechanical engineering efforts, focusing on concept development and prototype testing. I assessed the technical viability of designs, created initial prototypes, and played a pivotal role in fundraising and investor presentations. My work included developing visionary designs while de-risking the technology, from early concepts to functional prototypes, driving the technology forward and securing additional funding.

GOOD BUGGER AWARD

January 2022

The January Caliber Good Bugger award for the Christchurch team went to Aaron Johnson. Aaron is relatively new to the team and actually working remotely from Taranaki. We’re really proud of how he’s hit the ground running; completely acing a project for Fabrum Solutions, which has seen him take on a leading role in the project and produce excellent results. Awesome job Aaron!