Edwards Air Force Research Laboratory (AFRL)
Edwards Air Force Research Laboratory (AFRL) at Edwards AFB, California, is a premier aerospace propulsion research and testing facility in the Mojave Desert.
From 1999 to 2002, I supported the Research Operations and Support Services (ROSS) contract as a Mechanical Designer. The contract was awarded to Jacobs Sverdrup, who brought Applied Engineering Services (AES) on board as their engineering partner. I was the first employee AES brought onto their team for the ROSS contract, from General Physics Corp. Using SolidWorks and AutoCAD, I modeled and upgraded major rocket engine test facilities, including:
Test Stand 2A — large-scale horizontal stand for high-thrust propulsion testing.
Test Stand 1D — historic stand (vacant since the Apollo era) that I helped revive with detailed 3D models of piping, valves, control systems, and infrastructure.
I also developed new design/drafting standards and created the AES company logo, which is still displayed on Test Stand 1D.
General Physics had been great to work for prior to the contract transition — they even considered relocating me to support their Vandenberg AFB work.
Earlier with Computer Sciences Corp (1998–1999), I performed hands-on aircraft modifications on B-52, B-1, F-15, F-16, C-130, and others using 3D AutoCAD.
It was one of the most rewarding, hands-on periods of my career.
Test Stand 1D
Early SolidWorks Model (2001–2002)
Early 3D model of the main truss structure for Test Stand 1D. This was one of the first major projects where we transitioned from traditional 2D/3D AutoCAD workflows to SolidWorks, including the new piping package at the time. I was tasked with modeling the primary truss’ using simplified square tubing — later to be detailed with full I-beam structures during the refurbishment for modern high-thrust testing.
Note: Test Stand 1D is a high-capacity horizontal/vertical test facility (up to ~2.5 million lbs/ft thrust). While nearby stands like 1A and 1B were famously used for Apollo/Saturn engine testing, 1D was actively involved in various propulsion programs during that era.
Bonus detail on the marquee:
I also designed the new Applied Engineering Services (AES) logo shown on the facility banner. The original concept used three triangular shapes — I developed them into the clean, dimensional “AES” mark shown here.
AES Logo
Test Stand 2A
3D model of the horizontal rocket test stand. I was asked to lead the 3D modeling effort on this project.
Test Stand 2A in Action – Edwards AFB
Is a two-position horizontal test facility primarily used for component and subsystem testing of liquid rocket engines (especially LOX/LH2 systems). It is designed for thrust levels up to approximately 460,000 lbf (pounds-force).
This stand has supported numerous advanced propulsion technology programs, including turbopump testing, preburner development, and other critical rocket engine component validation for the Air Force Research Laboratory.
Test Stand 1A
One of the historic vertical test stands at Edwards AFB. This high-thrust facility was famously used for testing the massive F-1 rocket engines that powered the Saturn V during the Apollo Moon missions.
I first worked on Test Stand 1A shortly after being hired by General Physics at AFRL. While I wasn’t the lead designer, I supported several upgrades including additional support brackets and a redesigned mounting system for the external ignition torches used to burn off excess fuel. I also helped implement adjustable vertical steel supports with multiple hole patterns. This allowed the plumbing lines to be quickly reconfigured when switching between engine tests with and without the nozzle skirt — significantly reducing downtime between tests.
“I had the chance to witness a live hot-fire test on Test Stand 1A in my time at the AFRL. The ground shook under our feet, the heat from the engine was intense, and the massive steam plume rolled straight toward us. Standing there in goggles and a hard hat, I could actually reach out and touch the edge of the steam cloud right in front of me. It was one of the most powerful and surreal moments of my career.”
NASA Jet Engine Thrust Stand Upgrade – F-22 Raptor
Side project while at Applied Engineering Services (AES). NASA reached out to the team to modernize this thrust stand for testing the new F-22 Raptor aircraft.
The real photo shows the stand with an F-16. The 3D model is my work, developed from the structural FEA calculations performed by the AES engineering team.