Vaughan has an Electrical Engineering degree and taught Mathematics and Physics in various schools, eventually becoming Head of Science at a Comprehensive School in Chester for nine years. Seeking a new challenge, he transitioned into the electronics industry, working on the development of the first British robot. After eight years in industry, he returned to education as the Head of Technology at St Swithun's School in Winchester where he worked for 15 years, guiding students in technology and innovation. In addition to teaching, he worked part-time for Young Engineer Clubs, designing competitions as well as serving as a judge. He entered a team in the national expansion of the Greenpower F24 competition in 2000 and have since remained connected to Greenpower, becoming a trustee in 2005. Outside of his professional pursuits, Vaughan served on the Prince of Wales Committee for six years, he’s been a Hampshire County Councillor for eight years, and served on the Board of the South Downs National Park for four years. He also had the honour of being the mayor of Petersfield on two occasions, representing the local community.