Jeff Toycen

Engineer · Inventor · Industrial Designer

Jeff Toycen

50 years of building things that matter. From shipyards in Seattle to bomb disposal robots for 120 countries. From ballistic armor on Leopard tanks to precision machine tools trusted by NASA and SpaceX.

Ottawa, Canada · Since 1974

The Short Version

A life spent making things
that didn't exist before.

Jeff Toycen started as a boilermaker and journeyman shipbuilder at Marine Construction & Design and Lockheed Shipbuilding in Seattle, Washington. After leaving the shipyards in 1974, he studied engineering at South Seattle Community College while designing crane and material handling systems at Northwestern Crane — building and installing 140 crane systems for Boeing, Lockheed, Weyerhaeuser, and the Trident naval base.

In 1980, he moved to Canada and entered the aerospace machining sector. A certified welder in most metals and processes, machinist, and programmer, Jeff founded Terra Structures Corporation in 1985 — which became the fastest certified welding company in North America by 1987 (3.2 lbs/hour/man of controlled hydrogen deposit in steel).

In 1987, he formed Terra Aerospace Corporation, which rapidly became a just-in-time shipper for leading defense companies and produced a new generation of ballistic doors — now used in all Canadian embassies worldwide.

Through the 1990s, Jeff invented the Smart Pulley (Single line Mechanical Auto Release Technique), reconfigured hook-and-line kits for explosive ordnance disposal, and designed EOD robots that changed how police and military teams handle dangerous explosives in over 120 countries.

In 2003, he turned his attention to the machining industry, founding Cuttermasters. Today, Cuttermasters builds custom-engineered DC motor grinders trusted by NASA, SpaceX, Tesla, Apple, Rolls-Royce, the US Navy, and machine shops worldwide.

50+

Years Engineering

120+

Countries Using His Inventions

12+

Patents

35,000+

Machines in Service

Career Timeline

Five decades of building.

1974–1980

Shipbuilding & Crane Systems

Seattle, Washington

Journeyman shipbuilder at Marine Construction & Design and Lockheed Shipbuilding. Studied engineering evenings at South Seattle Community College. Designed and installed 140 crane systems at Northwestern Crane for Boeing, Lockheed, Weyerhaeuser, and the Trident naval base.

1980–1985

Aerospace Machining

Ottawa, Canada

Moved to Canada and entered the aerospace sector, working for prominent defense-related job shops. Certified welder in most metals and processes, machinist, and CNC programmer.

1985–1987

Terra Structures Corporation

Ottawa, Canada

Founded Terra Structures, which became the fastest certified welding company in North America — 3.2 lbs/hour/man of controlled hydrogen deposit in steel. Specialty structural steel projects.

1987–2000

Terra Aerospace — Defense & EOD

Ottawa, Canada

Formed Terra Aerospace Corporation. Just-in-time shipper for leading defense companies. Designed next-generation ballistic doors for Canadian embassies worldwide. Invented the Smart Pulley, hook-and-line kits, and EOD robots (Merlin, Predator, Scorpion, Breacher) used in 120+ countries. IP-networked robot command in 1993 — years ahead of the industry.

Predator EOD Robot with police vehicle
1995–2002

Network Command & Ballistic Welding

Ottawa, Canada

Developed the Wisdom COM project — PC-based command and control over IP networks for evidence gathering and collaborative render-safe procedures. In 2002, became one of only two certified ballistic steel welders in Canada recognized by KMW Germany (builders of the Leopard Tank).

2001–2004

Adaptive Pedals for Special Needs Kids

Ottawa, Canada

Designed and built SureFoot adaptive pedal plates — universal devices that attach to any bicycle pedal, enabling children and adults with cerebral palsy or foot orientation conditions to ride conventional bikes and trikes. Designed to look like a sleek contemporary pedal so kids wouldn't feel self-conscious.

2003–2005

Composite Armor & High-Speed Drilling

Ottawa, Canada

Under contract from IBD Germany, designed manufacturing systems for composite ballistic material (non-metallic armor) used on the Stryker Vehicle. Developed high-speed drilling of Hardox 400 armor — reducing production time from 2.6 hours on a waterjet to under 1 hour on a CNC machining center. This armor is used on thousands of US military vehicles.

2003–Present

Cuttermasters — Precision Machine Tools

Ottawa, Canada

Founded Cuttermasters to address deficiencies in the tool grinding industry. Patented DC PWM motor technology for variable-speed, reversing grinders with 0.0002" shaft concentricity. Acquired the CUTTERMASTER Professional trademark in 2020. Now trusted by NASA, SpaceX, Tesla, Apple, Rolls-Royce, the US Navy, MIT, and machine shops worldwide. 35,000+ machines in service.

Tradesman DC Bench Grinder
2007–2009

Bomb Bag & Contender UGV

Ottawa, Canada

Filed patent on the world's first disposable bomb containment vessel — the Bomb Bag (Variable Containment Vessel). Initiated the Contender Project — a multi-configurable, disposable, battlefield-capable UGV network appliance operating over tactical radio nets.

2010

Deepwater Horizon Oil Spill Response

Gulf of Mexico

Formed REGEN, a green energy engineering firm. Partnered with Pyrolyzer. Tasked with designing sea filtration systems for the Deepwater Horizon oil spill. Flown over the site by Governor Haley Barbour and BP. Designed two systems capable of separating millions of gallons of seawater daily — including the Sea Vac fluid-solids separator.

Intellectual Property

Patents & Copyrights

US #5,201,496Smart Pulley — Single Line Mechanical Auto Release
US #5,211,460Hook and Line System
CA #2,210,187Canadian Patent — EOD Equipment
US #6,748,617EOD / Robotics Patent (June 2004)
CA ©1,023,263Mill Master End Mills Handbook (Copyright, Sept 2004)
CA #2,545,605Variable Containment Vessel — Bomb Bag (2006)
US #11/415,066Variable Containment Vessel (US Application, 2006)
US #60/867,115Bench Top End Mill Grinding Device (2006)
US #61/178,367SPDC Speed & Direction Controller for AC Induction Motors (2009)
US #61/183,876Corner Radius Grinding System for Cutting Tools (2009)
US #9,089,946DC Grinding Bench Grinder — Tradesman DC (Issued July 2015)
US (2009)DCA Distributed Control Architecture for UGV Motor Control

Professional

Memberships & Certifications

International Association of Bomb Technicians and Investigators
Federation of American Scientists
American Welding Society
Canadian Welding Institute
National Defense Industrial Agency
Robotics Technology Consortium
Canadian Machine Tool Producers

Certifications

  • • Certified Welder — Most metals and processes
  • • Certified Armor Welder — Ballistic steel
  • • CWB Welding Supervisor (Registered)
  • • Certified by KMW Germany — Leopard Tank ballistic steel welding (one of two in Canada)
  • • Journeyman Shipbuilder
  • • CNC Machinist & Programmer

Notable Clients & Users

NASASpaceXTeslaAppleBoeingRolls-RoyceUS NavyMITJohns HopkinsCanadian Armed ForcesRCMPATFNational Research Council

Get in Touch

Let's talk.

Whether it's about engineering, a collaboration, or just to say hello — I'd like to hear from you.