Kaelan James Grafton
Personal Statement
Versatile aerospace engineer with expertise in aircraft design, systems integration, and performance optimisation.
Combines analytical rigour with practical methodology to solve challenging problems through first principles.
Bridges the gap between engineering fundamentals and business realities, effectively communicating engineering
principles to diverse stakeholders. Demonstrated ability to lead multidisciplinary programmes from concept
development through to product verification.
Career History
Developing a novel VTOL aircraft optimised for exceptional payload capacity and operational efficiency.
• Led the conceptual design phase with a multidisciplinary team of 8 engineers to define aircraft architecture and key systems
• Developed comprehensive aircraft modelling framework in Python, integrating engineering tools (MATLAB/Simulink, OpenVSP, AVL, Siemens NX) for rapid trade-off analysis and design optimisation
• Established version control system for design data, enabling structured collaboration across disciplines, concurrent development of multiple design iterations, and eliminating previous inefficiencies in data sharing
• Determined and wrote technical requirements for propulsion, hybrid power plant, and primary structures
• Managed technical development roadmap while maintaining hands-on engineering involvement in advanced systems design
• Led technical development of Thermal Management Systems, High Lift Devices, and Ice Protection Systems
• Supervised flight trials, installed instrumentation systems, and derived key insights from test data
• Responsible for Weights & Balance, developing methodologies and tools for estimating, tracking, and controlling aircraft mass properties
• Responsible for performance analysis, developing and implementing methods to evaluate aircraft point performance (take-off, climb, cruise, landing) and mission performance characteristics (range, endurance, payload capacity) through computational modelling and simulation
• Built and mentored engineering team through performance management, training, and career development
Led mechanical systems development for successful technology demonstrator aircraft program.
• Designed and developed primary flight controls including surfaces, mechanisms, and actuation systems
• Pioneered manufacturing method achieving 33% mass reduction and 50% cost/ time savings for the system
• Wrote comprehensive test procedures and designed custom test rigs to validate system performance
• Created detailed kinematic models incorporating static and dynamic loading for design optimisation
• Produced technical documentation to BS 8888 and GD&T standards, including critical tolerance analysis
• Conducted technical reviews across engineering disciplines and supported procurement/production activities
Defence start-up developing Unmanned Combat Aerial Vehicles for urban environments.
• Led vehicle architecture development, with responsibility for aircraft design methodology
• Designed and sized mechanical components through CAD and FEA, optimising structural efficiency whilst balancing mass, space, vibration, and thermal constraints
• Developed rapid prototypes for systems integration testing, validating design concepts and identifying improvements
Development of PYRAMID Reference Architecture for reusable mission systems.
• Applied Model-Based Systems Engineering methodologies to develop and document reusable avionics architectures
• Created detailed UML and SysML models using PTC Integrity Modeller to define system interfaces and component relationships
• Implemented architecture patterns supporting technology obsolescence management and cross-platform compatibility for defence avionics
On secondment from BAE Systems, I worked on the novel propulsion system SABRE – the Synergetic Air-Breathing Rocket Engine.
- Developed engine control software of several concurrent designs of increasing complexity.
- Integrated software changes with a physical test rig (hardware-in-the-loop), allowing for rapid testing and
verification. - Wrote test procedures for software verification and ensuring traceability with requirements.
- Integrated engine control system with high-fidelity dynamic models of the engine (model-in-the-loop).
Research & Technology – Long Range Sensing:
• Counter Unmanned Aerial Systems study investigating limitations of current drone sensing technologies, in-house capabilities, and market analysis.
• Exploration of an overall sensor management and fusion system working closely with academic partners and utilising the BAE Systems sponsored 2020 UAV Competition.
• Worked with technologists, research theme leads, and operational analysists to understand hypersonic interactions with sensor systems.
Chief Technologist Team – Strategic University Partnership Liaison:
• Primary role was to manage the company’s relationship with Cranfield University, a strategic university partner.
• Engaged with external business development managers and academics to identify key research areas and possible collaborative activities (funding, training, technology development, etc.).
• Organised engagement sessions and events between the company and the university, such as strategic meetings, steering groups, and the inaugural inter-university UAV competition.
• Disseminated information regarding the university across the business through the creation of documents and webpages detailing current work with the university and their capabilities.
• Supported the Chief Technologist and her team in achieving its goals.
Engineering Support System – Systems Engineer:
• Investigated the ability of upgrading functionality of the ESS software. Had to manage both internal and external requirements across several sub-systems.
• Managed requirements and traceability through IBM DOORS.
Part of the multinational aerospace and defence company, Cobham SATCOM designs and manufactures satellite communication antennas for land, sea and air operations.
• Led a major project, fault finding a problem related to a mechanically steered antenna’s gearbox/ motor sub-assembly.
• Collaborated with senior engineers to develop and test an antenna mounting plate for the Airbus A350, specially designed to not impart stresses to the composite airframe.
• Integral in producing and inspecting composite components, often working long hours to meet increased production targets.
• Implemented a system to reduce time a technician spent on a batch job by 50% by incorporating two unskilled operators. Generated initial designs for automating some parts of the process.
• Investigated failure of composite fairings under impact of hail using a pneumatic gun.
Education
Modules: General Management, Project and Programme Management, Design Driven Innovation Processes, Business Process Analysis and Engineering, Product Development, Operations Management, Cost Engineering, Manufacturing Systems Engineering.
Group Project: Air Sector Environmentally Sustainable Future Products and Services: A look into current sustainability trends and how these may impact the future products and services of BAE Systems Air Sector. Using a Multi-Criteria Decision Analysis 28 technologies were ranked against four criteria (Profitability, Energy, Waste, and Performance). The output of the analysis was used to create an impact vs effort matrix and a technology development roadmap. This informed the company which technologies would have the greatest impact on their sustainability strategy and when they should implement them.
Modules: Aeroelasticity, Aerospace System Development & Life Cycle Model, Aircraft Aerodynamics, Aircraft Performance, Aircraft Power Plant Installation, Aircraft Stability and Control, Computer Aided Design, Crashworthiness, Design and Analysis of Composite Structures, Design for Manufacture and Operation, Design of Airframe Systems, Detail Stressing, Fatigue Fracture Mechanics & Damage Tolerance, Finite Element Analysis, Flight Experience, Initial Aircraft Design, Integrated Vehicle Health Management, Landing Gear, Loading Actions, Reliability Safety Assessment & Certification, Structural Dynamics, Structural Stability.
Group Design Project: Collaborative design of an advanced technology low drag regional airliner for entry into service in the 2030 – 2035 timeframe name the A-17 Zephyr. Individually focused on the design and analysis of the secondary power system (SPS) as well as an alternative hybrid battery system. The aircraft included a boundary layer ingestion electric aft propulsor designed to provide a third of the total thrust during flight. It was designed as a more electric aircraft (MEA) and therefore the SPS distributes almost 1 MW of power throughout the aircraft. It does this by running at 270 V DC through a distributed power system that minimises mass and power losses. A battery APU allows the aircraft to operate in an all-electric mode while taxiing effectively reducing ground emissions to zero. The APU also provides supplementary generation capabilities in flight to meet peak demands in electrical power. A hybrid battery system was also designed as an alternative to powering the SPS and the aft propulsor. It was found that this system would only be effective for missions shorter than the A-17 Zephyr’s design range. Team lead on design and manufacture of the scaled physical model of the aircraft.
Individual Thesis: Damage Tolerance Numerical Analysis and Testing of CFRP Bolted Joints in Bearing following a Pull-Through Failure Event: This thesis seeks to answer if a bolted joint damaged in a pull-through failure event is able to still carry a load in bearing. Using experimental testing, optical microscopy and numerical analysis it was found that the laminates were still able to carry a load in bearing even after significant pull-through damage. Based on the testing, on average the pull -through damage reduced the ultimate strength in bearing of the laminate by 13.69 %. While the numerical analysis showed that the pull-through damage increased the failure index (using the Hashin failure criteria) by 6.2 %.
Modules: Mechanical Vibrations, Product Design, Manufacturing & Nanotechnology, Finite Element Analysis, Industrial Ecology, Fundamentals of Control Systems, System Design, Engineering Professionalism, Fluid Mechanics and Thermodynamics.
Final Year Project: Conceptualisation, design and building of an autonomous underwater vehicle (AUV). A topic was proposed by the supervisor to develop a tool to conduct oceanographic research. With such a large scope an exhaustive literature review was conducted to determine what tools were already available and what would be possible based on limitations. An AUV was chosen with a basic control system with 3 degrees of freedom. Challenges included designing the structure and control surfaces with already available materials, implementing new manufacturing techniques (such as 3D printing), and coordinating with both internal and external workshops.
Awards: Dean’s merit list 2014 & 2015.
A diploma based course with equal focus on academics and technical ability. The course includes a yearlong internship at a company and trains students in the use of a workshop including hand tools, measuring equipment, lathe work and welding.
Professional Capabilities
SolidWorks, Siemens NX, MATLAB/Simulink, Python, Abaqus, Nastran/Patran
Microsoft Office Suite , Project, Visio, IBM DOORS, Polarion
Giannopoulos IK, Grafton K, Guo S, Smith H. (2020) Damage tolerance of CFRP airframe bolted joints in bearing, following bolt pull-through failure. Composites Part B: Engineering, Volume 185, March 2020, Article number 107766.
Royal Aeronautical Society Member, Golden Key Honours Society
UK SC Vetted, UK Driving Licence, Class IV Commercial Diving License
Native English speaker, Conversational Afrikaans.