Client Context
A robotics startup needed a rapid prototype for a sensor‑driven embedded controller to validate their concept before raising funding.
The Problem
They lacked in‑house embedded expertise and needed a functional prototype within 6 weeks.
Objectives
- Build a working hardware prototype
- Implement sensor fusion
- Provide a stable firmware base
- Support future expansion
Architecture & Approach
I designed a compact ESP32‑based controller with modular sensor inputs, real‑time processing, and OTA firmware updates. The firmware was built using a layered architecture to support future modules.
Technologies Used
- ESP32
- C/C++
- FreeRTOS
- IMU sensors
- Custom PCB design
- OTA updates
Challenges
- Tight timeline
- High sensor noise
- Power constraints
- Rapid iteration cycles
Solution
A fully functional prototype with stable firmware, sensor fusion algorithms, and a custom PCB. Delivered with documentation, schematics, and a roadmap for production.
Outcome & Impact
- Client secured funding
- Prototype used in investor demos
- Reduced development time by 60%
- Provided a scalable architecture for future versions
Metrics
- 6‑week delivery
- 3 PCB revisions
- 8 sensors integrated
- 0 critical firmware bugs