Featured projects
Design - Build - Iterate
A selection of UAV systems I have created from concept to validation. Including additively manufactured airframes, PCB design, edge AI inference, and more.
Companion Computer + Mesh Software Stack
A plug-and-play solution that enables off-the-shelf drones to operate in swarms with encrypted mesh networking and onboard computer vision.
Companion Computer CAD V3
Carrier schematic
Version 3
Routing
Version 1
Designed
- Raspberry Pi carrier board for a long-range radio module, power distribution, and aircraft interface
- Reticulum mesh networking stack ported to MAVLink for drone command and telemetry
- Custom Linux build for bring-up services, telemetry routing, and packet transport
- Trained custom computer vision models for object detection and aircraft-based tracking
Key technical decisions
- 4-layer PCB design for high-current power routing, controlled impedance, and RF isolation
- ESP32 for real-time radio control from Linux, using Reticulum as the transport layer
- Custom software interface for ArduPilot flight controllers to command and control multiple drones simultaneously
- Simulation and testing of mesh networking and computer vision capabilities
Failure / debug story
On version 1, a bench test hotplug with 25V caused a short and smoke. I traced the issue to missing input-voltage protection on the power input.
Result
The next iteration added a TVS diode for hotplug protection and a higher 60V safety margin on the 5V buck.
3D printed VTOL aircraft
A flight-tested UAV. Focused on endurance, modularity, payload support, and autonomy.
First forward flight
VTOL field test
Airframe CAD
Internal electronics bay
Gimbal subassembly
Designed
- Simulation and analysis of flight dynamics, stability, and efficiency given different designs and airfoils
- Complete CAD modeling of aircraft and subassemblies with design for manufacturing and tolerance stackup considerations
- Airframe packaging, internal wire-routing design, and component integration
- Internal electronics assembly with ArduPilot configuration
- Post-flight data analysis and performance tuning
Key technical decisions
- Airfoil selection across desired flight envelope and performance characteristics
- Sliding rail system to accommodate different payload configurations and sensor packages with movable CG
- VTOL configuration for ease of use and increased forward flight stability as a sensor platform.
- Chose conservative power margins around transmitters and compute loads for field reliability.
Failure / debug story
As seen in the video, initial high throttle led to unstable porpoising behavior. Throttle was reduced halfway through and plane stabilized.
Result
Identified that the initial gain that mixed motor pitch during forward flight was too aggressive, causing oscillations. Reduced the gain and the aircraft became stable at higher throttle.
Snap Drone
An early modular magnetic drone-frame prototype that split the ESCs and motors on the bottom from the flight controller, camera, and VTX on top, so sections could be swapped without building a whole new drone.
Snap
Snap exploded
Designed
- CAD of the race-drone frame and upper and lower subassemblies.
- CAD of the circuit-board PCB and Gerber files for the reconnecting interface.
- Manufacturing of the carbon frame using water-jet-cut plates.
- Manufacturing of PCB sections with CNC-cut FR4 and hot-air assembly.
Key technical decisions
- Split the design so the flight controller and video system could be reused across other airframes.
- Kept the PCB intentionally simple, using it as a contact interface between the flight controller and ESC.
- Evaluated the frame under stress and vibration while preserving crash separation.
- Flight testing and validation of the modular interface.
Failure / debug story
Designing and creating a robust modular electrical interface with reliable mating and protection.
Result
Modified the design to use carbon to align the PCB and embed the PCB within the carbon structure for better protection.
Skills
Mechanical, electrical, embedded, and test work.
Practical engineering across CAD, wiring, Linux, radios, power, and field troubleshooting.
Mechanical
- Solid & surface modeling
- CAD assembly configuration
- GD&T / tolerance stackup
- Design for manufacturing
- CNC mill & lathe
- 3D printing & waterjet
Electrical
- Embedded PCB design
- PCB layout & Gerbers
- Power distribution
- High-current interconnects
- ESP32 peripheral integration
Embedded / Software
- Embedded Linux
- ArduPilot setup
- MAVLink telemetry
- Reticulum mesh
- Computer vision
- Python, C/C++, MATLAB
Simulation & Testing
- Flight dynamics
- Airfoil analysis
- FEA stress analysis
- PID tuning
- Flight testing
- Failure analysis
- Post-flight log review