Design, Develop, Deliver!

David Johnson - Winter Garden, Florida

Multi-disciplinary engineer with three decades of experience transforming complex ideas into manufacturable realities. Equally effective on the bench, behind the screen, or leading a team, I specialize in uniting design, development, and fabrication into cohesive solutions. My work integrates full-stack systems, rapid prototyping, and advanced manufacturing—focused on delivering results that are precise, scalable, and built to perform.

About:

My engineering career is grounded in practical craftsmanship and refined through decades of applied technical leadership. I began in fabrication and process engineering, developing a disciplined foundation in precision manufacturing and ISO 9000 / Six Sigma methodologies that continue to guide my approach to efficiency, quality, and execution.

Driven by curiosity and a readiness to meet complex challenges, I expanded into automation, software, and embedded systems—integrating mechanical, electrical, and digital disciplines into cohesive, production-ready solutions. This cross-functional expertise enables me to navigate ambiguity, lead multidisciplinary teams, and deliver systems that bridge design intent with scalable engineering outcomes.

At Disney Parks & Resorts Technology, I have led technical programs and product teams developing IoT, safety, and guest-experience platforms. I thrive in environments that demand innovation under constraint—where strategy, creativity, and precision must align to achieve measurable impact.

DIY.Engineering serves as an extension of that mindset: a personal innovation platform for exploring emerging technologies across design, fabrication, and software. It keeps my hands on the tools, my perspective current, and my ability to execute sharp.

The following career highlights and projects reflect that journey—engineering solutions that balance innovation, practicality, and enduring performance.

Story:

  • Disney Parks & Resorts Technology – Technical Lead, Emerging Technologies
    Lead design, development, and deployment of next-generation IoT, safety, and guest experience technologies across global Disney properties. Led the development of Test & Learn Lab, a multi-bay innovation facility for rapid prototyping, immersive testing, and pilot deployment. Delivered integrated solutions for environmental sensing, access control, and intelligent asset tracking—bridging hardware, software, and fabrication to accelerate innovation from concept to park-ready implementation.

  • IoT Systems Architecture & Product Development
    Architected advanced IoT ecosystems connecting custom sensors (infrared, environmental, and proximity) with AWS serverless architectures. Designed and fabricated field-ready enclosures, ultra-low-power firmware, and resilient communication systems. Delivered scalable solutions for resort safety, logistics, and environmental monitoring.

  • Fabrication & Prototype Engineering
    Blended digital fabrication, precision machining, and embedded systems design to create production-grade prototypes and specialized devices used in interactive guest experiences. Produced CNC-milled enclosures, smart sensors, and attraction hardware integrating mechanical, electrical, and visual effects for interactive theme park experiences.

  • DIY.Engineering – Product Innovation & Creative Fabrication
    Founder and lead designer of DIY.Engineering, a personal innovation lab and creative technology brand producing limited-run, hand-built products and maker tools. Portfolio includes the RKDR Solo II handheld arcade console, ProtoFlow maker-to-market collaboration platform, PDLC Smart Glass Controller, Custom CNC Pendants, and custom IoT lighting and sensor systems. Documented processes through YouTube.diy.engineering, sharing design, machining, and micro-fabrication techniques with a global maker audience.

  • Software & Systems Leadership
    Led full-stack engineering initiatives in custom developed enterprise-scale systems. Delivered solutions for textile management, operational logistics, and digital infrastructure modernization, incorporating SSO integration, CI/CD pipelines, and modular architecture standards leveraging AI to accelerate delivery.

  • Innovation & Mentorship
    Recognized for building cross-disciplinary collaboration between design, engineering and operations. Mentored diverse teams in mixed architecture, agile processes, and design thinking—empowering rapid iteration and scalable delivery across complex technology portfolios.

  • Media & Broadcast Technology (Disney–ABC Television Network)
    Developed enterprise-grade tools for marketing, asset management, and broadcast operations. Delivered robust applications and reporting platforms that enhanced collaboration, increased efficiency, and optimized real-time media workflows across the national network.

Highlights:

Disney Parks & Resorts Technology

  • Textile Order Processing System (TOPS)
    Architected and led the development of a high-throughput enterprise application managing resort textile workflows from order to fulfillment. Integrated RFID tracking, automation services, and a modular architecture to streamline operations across multiple facilities. Enabled real-time tracking, cost transparency, and full digital transformation of the legacy process. Deployed across The Walt Disney World Property.

  • DClean Custodial Technology of the Future
    Lead solution development and reimagination of IOT hardware and software tools to improve the custodial services strategy across The Walt Disney World Park. Lead development of custom Fill level Sensors leveraging low power communication (Sigfox, LoRa) and Time of Flight technology to report trash fill levels providing pro-active and advanced analytics to drive park operations efficiencies. Deployed 10,000 sensors across all five theme parks.

  • Disney Brothers Studio – Interactive Prop Display
    Engineered a replica interactive prop featuring the historically themed Disney Studio props that react to guest presence and gesture input. Integrated multi-display visual effects, microcontrollers, and advanced PDLC technology to create a dynamic storytelling experience blending art, history, and technology. Delivered as part of Disney Cruise Line’s immersive guest engagement initiatives.

  • Steamboat Willie Interactive Prop
    Developed a living art replica of the iconic Steamboat Willie animation cell that react to guest presence and gesture input. Integrated multi-display visual effects, microcontrollers, and advanced PDLC technology. Fabricated housing using CNC machining, custom electronics, and themed finishing to meet show-ready standards. Delivered as part of Disney Cruise Line’s immersive guest engagement initiatives.

  • Animator’s Desk Interactive Experience
    Created a responsive prop replicating a vintage animator’s workspace. Integrated lux sensors, digital video, innovative visual effects and PDLC technology to bring the desk to life—blurring the line between tangible and digital storytelling. Delivered as part of Disney Cruise Line’s immersive guest engagement initiatives.

  • Smart Park Lab – Test & Learn Facility
    Led the technical design and implementation of a multi-bay lab environment used to prototype and evaluate new technologies for Disney Parks. Integrated IoT devices, environmental sensors, audio-visual systems, and networked controls to simulate real-world guest environments and validate emerging concepts at scale.

DIY.Engineering Innovations

  • RKDR Solo II – Hand-Crafted Retro Arcade Console
    Designed and fabricated a limited-run, all-aluminum vertical arcade console integrating a custom PCB, retro game software, and hand-finished powder-coated housing. Merges precision CNC work, embedded firmware, and industrial design for a collectible-grade experience.

  • ProtoFlow – Maker-to-Market Collaboration Platform
    Built a full-stack platform empowering makers and clients to collaborate on new product development. Developed Supabase database schema, n8n automation workflows, and AI-driven milestone tracking. Integrates proposal, manufacturing, and delivery pipelines under one intelligent system.

  • PDLC Smart Glass Controller
    Created a Wi-Fi-enabled controller for polymer-dispersed liquid crystal (PDLC) smart film. Designed custom PCB, relay logic, and firmware to achieve smooth dimming transitions, remote control, and seamless integration into modern installations.

  • AS5600 Magnetic Spinner Dial
    Developed a high-precision interactive rotary input device utilizing the AS5600 magnetic encoder. Designed for creative control surfaces, interactive exhibits, and IoT dashboards.

  • Industrial & Environmental IoT Sensors
    Designed multiple low-power Sigfox and LTE-based sensors for environmental, proximity, and safety monitoring across Disney Parks and internal operations. Architected firmware, cloud connectivity, and ruggedized housings for extended field deployment.

Media & Systems Development

  • Enterprise Media Tools – Disney-ABC Television Network
    Developed enterprise-level applications for marketing, media asset management, and live broadcast coordination. Created data-driven dashboards, real-time reporting tools, and cross-platform integrations that enhanced operational visibility and responsiveness.

Projects:

I’m always open to conversations that challenge convention and push the boundaries of what’s possible in design, engineering, and innovation. Whether it’s leading technical programs, developing advanced prototypes, or exploring new fabrication technologies, I bring a disciplined, hands-on approach to delivering results that perform and inspire.

Let’s connect to explore how cross-functional engineering, design, and technology can drive your next initiative forward.

Let’s Talk:

Custom Product Development Showcase

  • A Custom CNC Pendant Controller

    Custom CNC Pendant

    with modern stylized aesthetics compatible with multiple open source CNC machines.

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  • Micro CNC Touch Probe

    Custom designed specifically to work under tight clearance constraints of modern desktop CNCs.

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  • A modern curved crcade gaming machine

    A Curved Arcade Machine

    with a twist on retro design. employing state of the art electronic components multiple arcade machine game emulator.

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  • An elegant CNC dust Shoe

    A Low-Profile CNC Dust Shoe

    It’s minimalist design & low-profile aerodynamics makes this CNC Dust Shoe out perform others.

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  • Scent-o-Matic

    Scent-o-Matic TV

    A custom Retro TV that plays videos synchronized to 8 scents for an immersive visual experience.

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  • Custom CNC Enclosure

    A Custom CNC Enclosure

    Maximum visibility and full access to work within the machine work envelope for efficient space utilization.

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  • Custom CV Camera Enclosure

    CV Camera Enclosure

    Milled from billet aluminum, an embedded, articulating camera mount with sapphire lens.

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  • Handheld Arcade Emulator

    Clear Acrylic, Custom Handheld vertical arcade emulation system for pure retro gaming mastery.

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  • Industrial Bite Guard

    Designed to capture 360 video and withstand the bite force of exotic animals, with a custom modular enclosure.

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  • Exploded Product Models

    designed for use in training to demonstrate the inner workings of multi-component product assemblies.

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  • Jedi Beer Tap

    Last Jedi Beer Tap

    a thermally controlled beer tap uses “the force” to pour the perfect pint while Lord Vader taunts you!

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