Acting mechanical team leadMAY – AUG 2026OTTAWA, ONTARIO · UAV DISTRIBUTOR & DESIGNER
AirMetal Robotics
Fixed-wing UAV development, instrumentation & validation
Worked across mechanical design, embedded sensing, test engineering and flight-electronics integration during a rapid aircraft-development program. Designed custom hardware around existing commercial components, built measurement systems, and used ground/flight data to evaluate prototypes rather than treating integration as a simple assembly task.
01 / Structural instrumentation & data acquisition
- Designed an ESP32-based wing measurement architecture to capture structural bending/deflection, loading response, vibration, acceleration and temperature during prototype testing.
- Selected and integrated existing sensing hardware, designed mechanical mounting/interfaces and wiring, and brought individual measurements together into one integrated test system.
- Acquired and processed measurements in Python, comparing measured structural response with calculations and theoretical expectations to guide design review and subsequent testing.
02 / Avionics, actuation & flight systems
- Integrated Pixhawk 6C / ArduPilot flight controllers with GPS, pitot airspeed sensing, radio telemetry, servo-driven control surfaces, battery monitoring and failsafe logic.
- Configured systems in Mission Planner, including preflight checks, flight modes and safety/geofence functions; debugged relationships between radio inputs, servos, ESCs and power distribution.
- Built four aircraft-level airspeed / ground-speed measurement integrations, collected data from commercial sensors and flight systems, and used the outputs to assess aircraft test behaviour.
03 / Aircraft & propulsion testing
- Helped fabricate, integrate and test four fixed-wing prototype aircraft, iterating mechanical layout, lightweight construction and integration of electronics and actuators.
- Designed propulsion-test hardware and characterized/tuned two-stroke gasoline engines using controlled thrust/performance testing.
- Prototyped landing-gear and other aircraft components, and built a water-agitation apparatus for waterproofing demonstrations and environmental-sealing tests.
04 / Electronics protection & rapid fabrication
- Designed and 3D-printed a flexible TPU enclosure for a valuable test PCB exposed to hard collisions during indoor UAV flight experiments, including impacts with the ceiling and ground.
- Used the PCB footprint, mounting, access and impact-exposure constraints to shape a protective enclosure intended to reduce risk to expensive electronics.
- Iterated fixtures and other prototype hardware using CAD and additive manufacturing under short development timelines; no quantified drop-survival rate is claimed for the TPU case.
05 / Acting technical leadership
- Served as Acting Mechanical Team Lead for part of the co-op, coordinating a four-person development effort, technical reviews, design priorities and communication with other functions.
- Helped manage engineering decisions and resource allocation within a program with a reported $100K+ development budget, balancing rapid prototyping with testability, schedule and integration risk.
- Maintained practical interfaces between mechanical prototypes, electrical systems and the software/controls workflow.





Publication review: aircraft photographs and employer-developed test hardware should be cleared for public portfolio use before deployment.













