Bradley Schalk

Aerospace · Design · Manufacturing · Testing

Aerospace Engineering student at the University of Illinois Urbana-Champaign, building, testing, and improving real hardware across CAD, manufacturing, robotics, and flight. I like engineering that crosses disciplines and does not stop at the model.

Portrait of Bradley Schalk.
Featured work

Projects

Aerospace design and CAD alongside production hardware, automation, and machining — carried from problem through design into something built and tested.

FANUC R-1000iA/100F robot and Yama Seiki BM-1600MAX vertical machining center in the automated track shoe cell.
Automation · Controls

FANUC Robot & VMC Automated Manufacturing Cell

Programmed and helped set up an automated cell in which a FANUC R-1000iA/100F six-axis robot moves track shoes between material racks and a Yama Seiki BM-1600MAX machining center — robot programming, PLC safety logic, custom end-of-arm tooling, and commissioning on a live cell.

  • FANUC TP
  • RoboGuide
  • PLC ladder logic
  • Sensors & I/O
  • CAD / CAM
  • Machine vision
Front-quarter Siemens NX render of the B-36 Peacemaker model above a cloud layer.
Aerospace · CAD

B-36 Peacemaker — Siemens NX Aircraft Model

A high-fidelity parametric recreation of the Convair B-36 built in Siemens NX, with constrained assemblies, moving mechanisms, rendered views, and an engineering animation.

  • Siemens NX
  • Large assemblies
  • Mechanisms
  • Animation
The fabricated hand-launched glider prototype seen head-on, showing the full triangular planform and the centre vertical fin.
Aerospace · Design-build-test

Hand-Launched Glider — Design, Fabrication & Flight Testing

Led a team through designing a glider from scratch, fabricating the prototype, and refining its stability through iterative testing — reaching a measured 179 ft flight over 6.35 seconds from a ground-level launch.

  • Team lead
  • CAD
  • Fabrication
  • Flight testing
Physical furnace conveyor roller and chain system used as the basis for the CAD/CAM replacement work.
Manufacturing · CAD / CAM

Furnace Conveyor Belt System

Modeled a furnace conveyor and its components from existing hardware, produced the CAM to machine them, built custom workholding, and assembled physical conveyor segments.

  • CAD assemblies
  • CAM
  • CNC machining
  • Workholding
Broken furnace component beside its newly machined replacement, with the fractured flange pieces in front.
Manufacturing · Reverse engineering

Furnace Replacement Component

A component in the heat-treatment furnace broke with no drawings available. I measured the damaged part, rebuilt its geometry in CAD, and supported manufacture of a replacement.

  • Hand measurement
  • CAD
  • Machining
Capabilities

Technical skills

Design & CAD

  • Siemens NX
  • Fusion 360
  • Part modeling and large assemblies
  • Constrained mechanisms and motion
  • Aircraft and aerospace geometry
  • Reverse engineering from measurements
  • Rendering and engineering animation

Build & test

  • Prototype fabrication
  • Flight testing and design iteration
  • Mechanical assembly and fit-up
  • Hand measurement and layout
  • Hands-on troubleshooting
  • 3D printing

Manufacturing

  • Fusion CAM
  • CNC machining and milling
  • Vertical machining centers
  • Custom workholding and soft jaws
  • Design for manufacturability

Robotics & controls

  • FANUC teach pendant (TP) programming
  • FANUC RoboGuide simulation
  • PLC ladder logic
  • Sensor I/O, interlocks, and safety devices
  • Robot–machine tool integration
  • Machine vision integration support
About

Close to the hardware, across disciplines

I'm an Aerospace Engineering student at the University of Illinois Urbana-Champaign who enjoys working close to the hardware and carrying ideas from design into the real world. My experience has ranged from aircraft CAD and flight testing to robotics, automation, machining, CAD/CAM, controls, manufacturing, and hands-on troubleshooting.

I'm especially interested in aerospace and space systems, but what I like most is engineering work that crosses disciplines and lets me understand, build, test, and improve a full system rather than staying confined to one narrow task.

Alongside coursework I've been involved with Liquid Rocketry at Illinois, including the Engine subgroup, and with ISS SpaceShot.

More about my background →

Degree
B.S. Aerospace Engineering
University
University of Illinois Urbana-Champaign
Graduating
May 2029
Location
Urbana-Champaign, Illinois
Involved with
Liquid Rocketry at Illinois (Engine subgroup) · ISS SpaceShot
Contact

Get in touch

Open to engineering internships and hardware-heavy project work. Email is the fastest way to reach me.