Aeronautical & UAV Systems Engineer with end-to-end ownership of autonomous drone development from bare-metal ESP32-S3 autopilot PCB design and ArduPilot HAL integration to ROS 2 swarm middleware and BVLOS field operations. Designed, built, and flight-tested custom flight controllers with EKF3 sensor fusion; commanded operations across a 20+ airframe fleet through 120+ sorties under DGCA UAS Rules 2021. Seeking to bring this depth across the full stack from sensor integration to autonomous mission execution at a company building mission-critical UAV systems.
Architected a full custom flight controller from schematic to airborne hardware: designed SPI bus topology for BMI270 IMU and BMP581 barometer at sub-10 MHz, resolving clock jitter and bus contention during firmware bringup. Wrote custom HAL interface mappings in ArduPilot for high-speed SPI sensor communication; validated EKF3 sensor fusion through a structured flight test matrix static hover (±1.2 m position hold), GPS-assisted loiter, and full autonomous waypoint execution confirming stable attitude estimation across all envelopes. Published complete flight logs, PCB schematics, and flight footage at github.com/yogesh031020/AeroCore-S3.
Developed a C++ boids algorithm swarm coordination library running inside isolated ROS 2 namespaces, enabling decentralized multi-agent path planning without a central broker or single point of failure. Integrated Eclipse Zenoh router for peer to peer telemetry synchronization, cutting active network overhead by 40% versus pure ROS 2 DDS validated by bandwidth and RTT profiling on Raspberry Pi 4 companion computers. Visualized real-time swarm state and collision avoidance boundaries in RViz2; full system validated in Gazebo Harmonic SITL before hardware integration.
Deployed a dual-core FreeRTOS architecture on an ESP32-S3 companion computer: Core 0 handling A* pathfinding and IR triangulation; Core 1 managing MAVLink telemetry and ultrasonic obstacle avoidance achieving <40 ms full control loop latency. Implemented a 4-beacon TSOP38238 IR sensor array for dynamic spatial triangulation, achieving ±3cm docking precision for automated payload pickup in GPS-denied warehouse environments. Deployed a TensorFlow Lite Micro model onboard for human-obstacle classification, triggering MG90S servo safe-release failsafes on detection.
Executed a closed-loop design iteration on a 3.0m High-Altitude Long-Endurance (HALE) UAV: aerodynamic shaping in OpenVSP, structural boundary certification in PrePoMax/CalculiX FEA, and low-speed regime validation via OpenFOAM CFD. Trained a PyTorch surrogate model on drag-weight trade surfaces across aspect ratio and spar geometry sweeps, achieving an 11.9% lift efficiency gain over the baseline all design decisions data-driven from CFD and FEA outputs.
Final Year Project: Prototype Design & Analysis of a Valveless Pulsejet Engine - propulsion systems, combustion analysis, structural testing
Professional Non-Destructive Testing (NDT) Level II Certification (UT, PT, RT) | Trinity NDT Engineers
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