John Dews-Flick

John Dews-Flick

Manager, Biomechanics Modeling Team at Align Technology

I'm an aerospace engineer, coder, and machine learning researcher who enjoys turning hard technical problems into useful tools. I lead biomechanics modeling at Align Technology and stay hands-on with simulation, AI systems, scientific software, and the occasional robot. Learn more about me

Selected Project Browser Demos

A little about my path

Experience & selected work

I like working where engineering, software, and curiosity overlap. Here are a few of the roles, projects, and classrooms that shaped how I build and lead today.

All
Education
Experience
Projects

Manager of Biomechanics Modeling Team - Align Technology

2026-Present • Position

Managing the Biomechanics Modeling Team at Align Technology, leading R&D engineers across treatment prediction models, shape optimization, unsupervised classification, simulation integration, and production AI workflows.

Team Leadership Machine Learning Biomedical RAG Systems

Align Knowledge RAG Platform

2024-2025 • Project

I developed a production-grade RAG system that ingested and indexed internal documents into a secure vector database with fine-grained permission controls. I evaluated multiple embedding models, built custom reranking methods, and designed metrics to measure retrieval relevance and system effectiveness. Additionally, I implemented LLM-based document ranking, elimination, sorting, and sanitization, and built custom agents and tailored solutions for specific teams

RAG LLM Vector Database Embeddings Reranking Production AI

RustFEA

2023-2025 • Open Source Project

Open-source project implementing Finite Element Analysis (FEA) using the Rust programming language. Provides a framework for running FEA simulations, leveraging Rust's safety, speed, and modern language features for high performance and reliability.

Designed for both research and practical engineering applications, offering computational techniques for solving complex structural, thermal, and other physics problems by discretizing them into smaller, manageable elements.

Finite Element Analysis Rust Scientific Computing Open Source Computational Mechanics

Align Simulation Platform

2024 • Project

Automated and pioneered new simulation and analysis methods for orthodontic treatment planning.

Implemented distributed simulation compute on premise to enable grander statistical use of the simulation platform and data collection for machine learning applications.

Simulation Distributed Computing Machine Learning Orthodontics

WASMBrowserMLP

2024 • Interactive Demo

Interactive web demo that visualizes the training of a Multi-Layer Perceptron (MLP) neural network in real time, entirely in the browser using WebAssembly for high performance. Core neural network logic implemented in Rust and compiled to WASM, with Vue.js frontend.

Demonstrates 2D binary classification where the model learns to distinguish points inside user-defined regions using configurable architectures, loss functions (MSE/BCE), and complex mask expressions. Users can watch decision boundaries evolve in real time.

Phase Plane
WebAssembly Rust Neural Networks Binary Classification Real-time Visualization

BrowserFlow

2026 • Interactive Demo

Browser-based Euler fluid flow simulation that runs interactive fluid dynamics directly in the browser.

Built as a visual scientific demo for exploring flow behavior and numerical simulation concepts without installing local tooling.

Euler Fluids Fluid Simulation Open Source JavaScript

Quad-Sim

2026 • Interactive Demo

Browser-based quadcopter simulation for exploring vehicle dynamics, controls, and flight behavior through an interactive demo.

The project extends my simulation work into robotics and autonomous systems, emphasizing approachable experimentation with nonlinear motion and feedback control.

Quadcopter Robotics Controls Simulation

R&D Engineer III / Team Lead - Align Technology

2023-2026 • Position

Leading a team of R&D engineers in the development of machine learning prediction models tied with simulation to provide patient specific design.

Developed and validated custom machine learning models for biomedical optimization. Pioneered a RAG knowledge base chat system tailored for domain specific and agentic use.

Team Leadership Machine Learning Biomedical RAG Systems

R&D Engineer II - Align Technology

2022-2023 • Position

Pioneered new simulation and analysis methods for quantifying the effect of orthodontic appliances in highly patient specific morphology.

Provided new insight and data metrics for previous and future cases, advancing personalized treatment planning.

Simulation Analysis Orthodontics Patient-Specific

Non-Linear Frictional Contact Simulation

2022 • Master's Thesis
Phase Plane

Master's thesis for the University of Florida which applies the step-boundary method to contact analysis within FEA.

Contributed to novel software OnSimulation with analytical geometric representation for contact identification and analysis of stick-slip problems.

Finite Element Analysis Contact Simulation Research IBFEM

OnSimulation Contact Analysis Add-on

2022 • Software Launch

Launched contact analysis add-on using the immersed boundary method within the finite element analysis software OnSimulation.

Implemented novel geometric representation techniques for improved contact identification and analysis.

Software Development FEA Contact Analysis Product Launch

Master's in Aerospace Engineering

2021-2022 • Education

Extensive understanding of solid mechanics, simulation and the FEA method, including system design, plasticity, and contact analysis.

Completed thesis on contact simulation in IBFEM on a novel method to represent contact without meshes. Also served as Graduate Teaching Assistant for FEA and computational CAD courses.

Aerospace Engineering Solid Mechanics FEA Teaching

Web Based FEA Solver

2021 • Demo Project

Browser based 2D finite element software for solid mechanics problems which uses the immersed boundary method.

Demonstrated the feasibility of running complex FEA calculations directly in web browsers, making simulation more accessible.

FEA Example

test

Web Development IBFEM Browser-based FEA Innovation

BallTableDynamics

2021 • Interactive Demo

Interactive web application that simulates the dynamics of a ball on a table using intuitive 3D visualizations. Built with Vue.js and powered by the three.js graphics library.

Allows users to explore physical motion and control systems through real-time, browser-based simulations with interactive 3D graphics.

Phase Plane
Physics Simulation Vue.js Three.js 3D Graphics Control Systems

KeplerSolverUI

2020 • Interactive Demo

Interactive web-based application that streamlines the process of solving Kepler's Equation, a core concept in orbital mechanics and astrodynamics.

Implements robust numerical solvers using Newton-Raphson method with real-time visualization of orbital paths and parameter relationships. Features modern JavaScript frameworks with plotting libraries for dynamic user experience.

Orbital Mechanics Numerical Methods JavaScript Visualization Educational Tool

Graduate Research Assistant

2020-2022 • Research Position

Research within finite element analysis on non-linear frictional contact contributing to the novel software OnSimulation.

Contributed significantly to analytical geometric representation for contact identification and analysis of stick-slip problems.

Research FEA Contact Analysis Software Development

Bachelor's in Aerospace Engineering

2017-2021 • Education

Coursework includes orbital dynamics, flight dynamics, CFD, Monte Carlo simulation and control theory.

Experience with material testing, machining and additive manufacturing. Graduated Cum Laude with strong foundation in engineering principles.

Aerospace Engineering Orbital Dynamics CFD Control Theory

Phase Plane

2019 • Computational Tool

Computational tool designed to visualize and analyze the phase portraits of dynamical systems, primarily focusing on systems of ordinary differential equations (ODEs).

Plots vector fields, trajectories, equilibrium points, and nullclines, providing valuable insights into the qualitative behavior of two-dimensional dynamical systems. Supports interactive exploration and parameter adjustments for teaching and research applications.

Phase Plane
Dynamical Systems ODEs Web Visualization Mathematics

OrbitalElementsJS

2019 • Open Source Library

JavaScript library for solving orbital mechanics problems, allowing conversion between orbital elements and position/velocity vectors for two-body orbital systems.

Features interactive demo with 3D visualization, supports standard Keplerian orbital elements, and provides both forward and inverse transformations. Built with Vue.js frontend and published as an NPM package.

Orbital Mechanics Web Simulation Aerospace

Senior Developer - Catch The Fever

2015-2023 • Position

Single-handedly developed a robust, automated e-commerce platform now driving multi-million dollar revenue.

This system handles orders, retail orders, shipping, notifications, and ad optimization with fully automating fulfillment down to label selection and printing.

E-commerce Full-Stack Development Automation Revenue Generation

Junior Developer - IJoin Solutions

Summer 2015 • Internship

Designed and implemented a real time notification system within a financial advising and onramp software.

First professional software development experience, working with real-time systems and financial technology.

Software Development Real-time Systems Financial Technology

Featured Projects

Inventorship

Patents

2023

Direct fabrication of orthodontic aligners

Published patent application WO2023183884A1 for direct fabrication approaches supporting orthodontic aligner manufacturing.

Published
2025

Orthodontic biomechanics patent pending

Pending patent application tied to biomechanics modeling, simulation, and treatment prediction work at Align Technology.

Pending
2026

Orthodontic modeling patent pending

Pending patent application extending work in patient-specific modeling, optimization, and production clinical engineering workflows.

Pending

About Me

I've always liked building things and understanding how they work. My background is in aerospace engineering, and today I manage the Biomechanics Modeling Team at Align Technology. I'm happiest moving between research and implementation—developing a model, validating it, writing the software, and helping a team turn it into something genuinely useful.

Machine learning: I build production RAG systems, prediction models, evaluation loops, and the data pipelines that make them dependable.
Simulation: My engineering roots are in FEA, contact mechanics, biomechanics, optimization, controls, and scientific visualization.
Always building: Away from my day-to-day work, you'll usually find me experimenting with Rust, WebAssembly, embedded systems, robotics, 3D printing, or photography.

Current Focus

  • Leading biomechanics modeling R&D
  • Production simulation and ML systems
  • FEA validation and scientific computing
  • Browser-native scientific tooling
  • PCB design, 3D printing, embedded systems, and robotic control

Education

M.S. Aerospace EngineeringUniversity of Florida · 2022
B.S. Aerospace EngineeringUniversity of Florida · 2021 · Cum Laude