Mechanical & Aerospace Engineering Student | University of Virginia
Javier De Leon-Flores

Designing hardware for impactful, real-world environments

Building mechanical systems, test hardware, and prototypes for aerospace, robotics, and engineering applications.

Municipal Electrical Infrastructure Security Product

Corner Strap

Corner Strap installed prototype on electrical box Corner Strap CAD assembly mounted on enclosure Corner Strap finger-joint mechanism CAD detail

Objective: Improve theft deterrence and field deployment for municipal electrical boxes while simplifying the lock body for manufacturable production.

Method: Redesigned the mechanism into a simplified finger-joint body, validated joint engagement with SolidWorks motion and tolerance checks, and produced fabrication-ready drawings.

Results: Reduced part count from 11 to 4, improved locked assembly robustness, supported manufacturer geometry refinement, and achieved a 10% manufacturing cost reduction with a fabricated prototype.

Lunar Regolith Excavation Ā· Competition Hardware

Bucket Drum Rover

Bucket drum rover CAD or prototype view 1 Bucket drum rover view 2 Bucket drum rover operating in regolith testbed

Objective: Design and manufacture a spinning bucket drum-based rover to excavate and build berms in a Lunabotics-style testbed.

Methods: Used SolidWorks for full CAD and FEA, then fabricated components via water jet, Prototrak mill, roller forming, and welding.

Results: Achieved 5th overall at NASA Lunabotics 2025 and earned the Innovation Award and the Granular Mechanics Award.

Mass Optimization Ā· Planetary Loader

Front Loader Rover

Front loader rover initial concept CAD Front loader rover chassis and wheel arrangement Refined lightweight front loader design

Objective: Design a front loader that maintains high digging capacity and rate while significantly reducing mass versus conventional designs.

Methods: Modeled designs in SolidWorks and Onshape; ran FEA on bucket structures to assess strength under digging and tipping loads.

Results: Shifted the center of mass between the wheels, enabling roughly a 20 kg mass reduction compared to typical front loader layouts.

Fluid-Driven Excavation Ā· Cyclone Separation

Vacuum-Powered Excavator

Vacuum excavator cart CAD layout Side view showing airflow path and cyclone separator Handheld digging or core sampling attachment

Objective: Create a vacuum-based excavation tool capable of efficiently removing soil and debris while separating and storing solids.

Methods: Modeled airflow paths in SolidWorks and integrated a cyclone separator feeding a modular dirt compartment.

Results: Demonstrated effective dirt removal driven purely by fluid suction and filtration, generating interest from companies such as Home Depot.

UAV Payload Ā· Precision Optics

Roku F1GIM2 Universal Lens Mount

Drone lens mount CAD model with gear teeth FEA stress plot of lens mount under load Assembled lens mount installed on UAV

Objective: Design and manufacture a universal filter lens mount for the Roku F1GIM2 UAV that maintains low mass and allows fine angular adjustment.

Methods: Built detailed 3D models in SolidWorks and used static FEA to validate strength of weight-saving pockets and gear teeth.

Results: Produced a compact mount with a gear system that enables precise rotation of multiple filters during flight.

Biomechanics Ā· Assistive Device

Simply Stretch – Full-Body Stretching Machine

Simply Stretch initial CAD configuration Simply Stretch physical prototype under test Refined stretching machine CAD with simplified frame

Objective: Develop a full-body stretching machine that can be used for physical therapy and recreational or senior fitness contexts.

Methods: Created a full assembly in SolidWorks and used FEA to compare different chassis geometries while holding aluminum stock constant.

Results: Built and tested two chassis iterations; the second design maintained similar strength with reduced material usage and improved simplicity.

About

My work focuses on mechanical design, experimental hardware, and aerospace applications where weight, reliability, and manufacturability are tightly constrained.

I enjoy taking designs from CAD and FEA all the way to fabricated hardware: cutting parts on a water jet or mill, welding and assembling, and then learning from how systems perform in real conditions.

I’m especially interested in planetary surface operations, UAV payload integration, and fluid-driven devices for excavation and handling granular materials.

Contact

I’m open to internships, research positions, and collaborations related to mechanical and aerospace systems, robotics hardware, and experimental prototyping.