On 1 May 2016, Vaughan joined AFC Ann Arbor in the National Premier Soccer League (NPSL) while still attending college. He would also sign for the club again for the 2017 season.
On 1 May 2018, Vaughan joined the Michigan Bucks for the 2018 season.
On May 1st of the following year, Vaughan joined Detroit City FC in the NPSL. On 2 February 2020, Vaughan left the club becoming a free agent.
On 2 August 2020 after not playing for a club in over six months, Vaughan signed for Eastbourne Borough in the National League South officially returning to England. He made his debut in a 3–0 loss against Dorking Wanderers. He would make a total of 16 appearances for the club.[2]
On 23 August 2021, Vaughan rejoined his former club Detroit City FC in the National Independent Soccer Association. On 29 August, he made his debut since returning in a 1–0 away win against Chicago House AC.[3] On 15 September, he scored his first ever goal in a 4–0 win against Maryland Bobcats and he even assisted a goal for Pato Botello Faz.[4] Vaughan made a total of 11 appearances and won his team the league title.
On 12 February 2022, Vaughan re-signed for Eastbourne on a free transfer. He made his second debut for Eastbourne in a 1–1 draw against Chippenham Town.[5] On 18 April 2022, Vaughan received the first red card of his career in a 3–0 home loss against Havant & Waterlooville, he would receive a three-match suspension in a challenge for the ball against James Roberts. He would make his return in the playoffs against Oxford City, but the match would end 2–0 loss away, ending their hopes of winning the title. Vaughan made 8 appearances for the club in the 2021–22 season.
On 20 July 2022, Vaughan extended his contract until the end of 2022–23 season. On 6 August 2022, Vaughan made his first appearance of the season in a 3–1 win against Oxford City. In the 2022–23 season, Vaughan made 30 appearances with zero goal contributions.
On 28 June 2023, Vaughan joined Welling United, another club i the National League South on a free transfer.[6] On 5 August 2023, he made his debut in a 5–2 loss against Truro City.[7] On 8 November 2023, Vaughan and Welling United parted ways. after making just 11 appearances for the club.[8]
On 9 January 2024, Vaughan signed for the Richmond Kickers in USL League One.[9] He made his debut for the club on 13 March 2024, in a 2–1 loss against expansion club, Spokane Velocity.[10] On 27 April 2024, he assisted a goal for Ryan Sierakowski in the USL Cup in a 1–1 draw, and the Kickers would win 4–6 on penalties.[11] He made 29 appearances in the 2024 season across all compitions while scoring getting no goals and only getting one assist.
On 7 March 2025, Vaughan made his debut for the 2025 season in a 4–2 win against Tormenta FC.[12] On 19 March, Vaughan scored his first goal for the Kickers in a 3–1 upset against Virginia Dream FC in the first round of the U.S. Open Cup.[13] He would make a total of 20 appearances across all competitions with only scoring one goal. He would leave the club following the 2025 season.[14]
On 4 February 2026, Vaughan signed for the Chattanooga Red Wolves in USL League One.