From Aerospace to Clean Tech: How Johnston Engineering Uses Analysis-Driven Design to Solve the Toughest Engineering Challenges
In a recent episode of the Industry Ignited podcast, host Dr. Leeanne Aguilar sat down with Andy Johnston, PE, Principal Mechanical Engineer at Johnston Engineering, licensed professional engineer in Washington State, and instructor of mechanical engineering at Gonzaga University. With more than 20 years of expertise in product development, advanced analysis, and mechanical design, Andy has built a career tackling technical challenges in industries ranging from aerospace to renewable energy.
What sets Johnston Engineering apart? A commitment to analysis-driven design, precision problem-solving, and a deep understanding of how to scale breakthrough technologies from lab to market.
From Aerospace Roots to Entrepreneurial Innovation
Andy’s journey began in aerospace, where he worked on electronics cooling and packaging for extreme environments—designing systems that could withstand frigid high-altitude flights and scorching desert landings. His experience at companies like Parker Aerospace taught him the value of physics-based simulations in saving time, reducing costs, and ensuring safety.
When Parker announced plans to consolidate operations, Andy saw an opportunity. On the same day he completed his exit interview, he collected his first invoice for Johnston Engineering. From there, he began building a company that applies the rigor of aerospace engineering to industries such as clean technology, biotech, and advanced manufacturing.
Turning Big Ideas Into Market-Ready Systems
Johnston Engineering specializes in helping clients transform ideas into tested, scalable products. Their services span four key areas:
Design – Developing detailed CAD models and 3D system representations.
Analysis – Using advanced tools like ANSYS for structural, thermal, and fluid flow simulations.
Build – Fabricating and integrating hardware through in-house capabilities and a network of partners.
Test – Conducting validation, performance testing, and full system integration.
A hallmark of their work is customizing shipping-container-based systems—from CO₂ capture units to flow batteries and energy storage systems—that can be deployed anywhere in the world. This mobility allows clients to test innovations across environments without the need for permanent infrastructure.
Why Analysis-Driven Design Matters
Unlike firms that separate design and analysis, Johnston Engineering tightly integrates the two. This fast iteration cycle ensures that prototypes are structurally sound, thermally stable, and cost-efficient—before clients invest in large-scale builds.
As Andy explained, “Nothing flies until it’s analyzed. The cheapest failures are the ones that happen on a computer screen.”
By coupling creative design with rigorous simulation, Johnston Engineering reduces client risk, shortens development cycles, and helps innovations reach market faster.
Powering the Future: Clean Tech, Carbon Capture, and Hydrogen
Looking ahead, Andy sees energy as the defining challenge of the next decade. With growing demands from AI data centers, the retirement of coal plants, and the push for renewable sources, Johnston Engineering is heavily engaged in:
Energy storage systems like flow batteries
Carbon capture technologies (direct air capture and source-based solutions)
Hydrogen infrastructure as a clean energy carrier
These solutions not only address the coming energy crisis but also create scalable, sustainable pathways for industries worldwide.
Built on Values: Integrity, Excellence, and Improvement
At its core, Johnston Engineering operates on three principles:
Integrity – Always acting in the client’s best interest and maintaining transparency.
Excellence – Delivering the highest-quality work across design, build, and analysis.
Continual Improvement – Investing in employee growth, ISO 9001 compliance, and internal process refinement.
These values ensure every project is handled with the rigor of aerospace engineering and the agility of entrepreneurial innovation.
Advice for Innovators
For entrepreneurs with promising ideas, Andy offers clear advice: build a strong team, move fast, and don’t aim for perfection right away.
“Innovation is a race,” he explained. “If you’ve identified a big problem, others are working on it too. Go all in, move quickly, and refine along the way.”
Listen to the full episode.
Interested in being featured on the podcast? Reach out to podcast@industryignited.com
