Ron Burgess

Hands‑on electro‑mechanical builds, prototype → production

30+ years across RAF airframes, automotive, and advanced thermal systems. I design fixtures, build and test complex assemblies, and turn first articles into repeatable low‑volume production.

new-me-2025.webp

Areas of Expertise

Test Rig Builds | Prototype Fabrication | Short Run Production



  • End-to-End Technical Project Delivery From early-stage concept through to on-vehicle testing, I have repeatedly delivered complex engineering projects on time and under real-world constraints. My background includes managing grant-funded innovation, building test benches for universities, and field-testing systems in both automotive and built environments.



  • Multi-Disciplinary System Integration Across roles from the RAF to Hexotherm, I’ve integrated mechanical, electrical, and thermal systems into working products — often in environments where no blueprint exists. I thrive at the intersection of engineering disciplines, blending prototyping, fabrication, and systems thinking to solve unique technical challenges.

  • Adaptive Problem Solving Under Pressure Whether restoring legacy equipment, fault-finding EV systems, or leading first-of-kind PCM builds, I excel in diagnosing and resolving issues in real time. My ability to switch between precision tools and big-picture thinking allows me to deliver results in fast-moving, resource-limited settings. 

Selected Works



transparent-roadsyphon-1024x870.webp

RoadSyphon – PCM Thermal Store

Prototype hot‑water system storing vehicle waste heat. Led build, test rigs, and DFM for low‑volume production.



20220425-135440.webp

Electro‑Mechanical Assembly Jig Suite

Custom fixtures, torque guides, and go/no‑go gauges boosting repeatability and takt time.

dsc-0133.webp

EV Battery Cooling Prototype

Built and validated thermal management rigs; rolling‑road and chamber testing.

dsc-0209.webp

Wiring Harness & PCB Integration

Crimping, soldering, looms, and PCB sub‑assemblies with test benches for QA.

dsc-0158.webp

CNC & 3D Printed Tooling

Low‑cost tooling and assembly aids combining 3‑axis CNC and FDM prints.

front-of-monobloc.webp

Hydraulics & Pneumatics Builds

Leak‑tight assembly, pressure testing, and documentation for serviceability.

Key Qualifications

Certifications: IMI Certified Automotive Engineer • F‑Gas • ECS JIB • CIBT Brazing • IOSH Managing H&S

NPORS (Telescopic Handler, Overhead Crane, Slinger/Signaller)

1. Electrical Installation & Testing

C&G 236 Part 1 & 2 – Electrical Installation IET 17th Edition Amendment No.1 Portable Appliance Testing (PAT) JIB Registered Electrician

2. Mechanical Fabrication & Fitting

NVQ Level 2 – Engineering Manufacture NTC Fabrication & Welding Certificate CIBT Commercial Pipe Brazing Cert Plant Mechanic Experience

3. Automotive & EV Systems

NVQ Level 3 – Vehicle Service & Repair C&G 383 Vehicle Servicing & Repair Pt 1 & 2 EV Service Engineer (Tec Serv Ltd) Battery, LPG & Petrol Systems Servicing

4. Thermal Systems & Refrigeration

F-Gas Refrigeration Certification HVAC Systems Installation & Maintenance Refrigeration & Heat Pump Fabrication (Sunamp)

5. Systems Integration & Controls

PLC, HMI & SCADA (Healthmatic) System Integration (PCM, electrical, mechanical) Mechatronics across sectors

6. Safety, Compliance & Leadership

IOSH Managing Safely COSHH, H&S (RAF & Civilian Roles) Field Team Leadership (RAF, Garage, Install Roles)

7. Specialist Technical Competencies

C & G Aeronautical Engineering Pt 1 & 2 (RAF) ECS JIB (Electrical Fitter & Automotive Electrician – pending SJIB transfer) Rapid prototyping and test rig design (multi-sector application) Mechatronics and system-level fault finding Cross-discipline integration (thermal, mechanical, electrical)

8. Industrial Equipment & Operations

NPORS Telescopic Handler (due renewal) NPORS Overhead Crane (due renewal) NPORS Slinger / Signaler (due renewal) Full Clean C1E & D1E Driving Licence Field testing and long-term vehicle validation (on-road & environmental chambers)

9. Project Execution & Communication

SQA Level 6 – Media Production (content delivery) Grant project delivery experience (e.g. TRIG, DIANA – practical, cross-functional delivery) Field team leadership (RAF, Hexotherm, Sunamp) COSHH & Health and Safety experience (civilian and military environments) Technical documentation and public engagement (via YouTube, prototypes, investor decks)

Experience

Contact

Based in the Scottish Borders • Frequently on‑site in Edinburgh. Available for hands‑on roles and short‑notice trials.

dsc-0136.webp