FEMTO 3D FOUNDER: 200+ PROJECTS • 50+ CLIENTS

PORTRAIT:

MEng ECE • UWINDSOR (GPA 9.2/10) • WINDSOR, ON

Abdul Fazil Abdul Salam — Embedded Systems & 3D Prototyping Engineer

Hello, my name is

Let's work together! ↗

Abdul Fazil

200+ Prototypes delivered for 50+ clients as Founder of Femto 3D

₹1,00,000 TNSI 2022 National Award Winner for BCI-Controlled Bionic Arm

9.2 / 10 MEng ECE GPA at University of Windsor (BEng CGPA 8.7/10 Distinction)

59% Lower Tracking RMSE via 100 Hz LQG Kalman Controller (200-run Monte Carlo)

INTERACTIVE FLAGSHIP SYSTEM BREAKDOWN

How 3D Printing & Embedded Hardware Come Together.

Explore the actual architecture behind my TNSI 2022 National Award-Winning BCI-Controlled Bionic Arm and Femto 3D builds—combining Autodesk Fusion 360 3D printing, a custom Autodesk Eagle TL074 bio-potential PCB, and Embedded C + Python/TensorFlow control.

ACTUAL 3D-PRINTED PROTOTYPE

SIDE PANEL & INTERNAL ELECTRONICS DRAWER SIDE EXPLODED (85%)

Closed Panel Panel Open Side Exploded

3D CAD: Drag to Rotate • Scroll to Zoom • Slider Opens Side Panel & Electronics

FUSION 360 + PLA 7 Iterations • 1.4–1.5 kg Total Weight • 10 Finger Gestures

EAGLE 2-LAYER PCB TL074 Op-Amp • 20–500 Hz Bandpass • 50/60 Hz Rejection

ARDUINO + TENSORFLOW Embedded C PWM Servos • ~50 Validation Trials

VERIFIED ENGINEERING PORTFOLIO

Projects & Hardware Systems

BCI-Controlled Bionic Arm for Upper Limb Amputees

Fusion 360 • PLA (1.4–1.5 kg) INR 1,00,000 TNSI Winner

01 // EMB • ROB • AI 2022 • 7 CAD ITERATIONS

BCI-Controlled Bionic Arm for Upper Limb Amputees

Built a mind-controlled prosthetic arm that moves only when the user's brain signal and a camera both confirm the target, winning the INR 1,00,000 TNSI 2022 national innovation prize (Government of Tamil Nadu).

CAD & 3D PRINT Fusion 360 • 7 Iterations PLA

EMBEDDED & AI Arduino C • EEG/EMG • TensorFlow

Femto 3D Neural Amp v0.1 Bio-Potential Amplifier PCB

Femto 3D • Neural Amp v0.1 TL074 Analog Front-End

02 // EMB • ANALOG PCB 20–500 Hz BANDPASS • 50/60 Hz NOTCH

Custom PCB: Dual-Stage Bio-Potential Amplifier (Neural Amp v0.1)

Designed a custom bio-potential amplifier PCB in Autodesk Eagle (Femto 3D Neural Amp v0.1) using a TL074 low-noise op-amp that boosts µV to mV EMG/EEG signals with integrated 20 to 500 Hz active bandpass filtering and noise rejection for the BCI bionic arm.

PCB HARDWARE Gold ENIG • Femto 3D v0.1

SIGNAL CHAIN TL074 • µV→mV EMG/EEG

3D-Printed Quadruped Walking Robot with Ultrasonic & Servos

3D-Printed Chassis & Legs Servo Gait • Ultrasonic Eyes

03 // ROB • EMB • 3D SERVO DRIVEN • HC-SR04 AVOIDANCE

Quadruped Walking Robot (Custom 3D Chassis)

Designed and fabricated a 4-legged walking robot with a 3D-printed modular chassis and leg linkages, multi-servo coordinated articulation, front HC-SR04 ultrasonic sensor navigation, and onboard LiPo battery integration.

MECHANICAL Fusion 360 Printed Chassis

EMBEDDED Embedded C • Arduino Mega

Surveillance Quadrotor built at AIRC Lab with RadioLink Transmitter

Pixhawk • ArduPilot RadioLink T8FB • 1 km

04 // ROB • CTRL • EMB 2025 • AIRC LAB UWINDSOR

Surveillance Quadrotor (AIRC Lab, UWindsor)

Built a camera-equipped surveillance quadrotor on a Pixhawk 2.4.8 PRO running ArduPilot, with GPS mapping, a live video feed, geofencing, and a return-to-home fail-safe, verified in flight out to a 1 km range.

FLIGHT CONTROLLER Pixhawk 2.4.8 PRO • GPS

AUTONOMY ArduPilot • Geofencing • RTH

Real-Time LQG Lane-Change Controller MATLAB and Kalman Simulation

100 Hz LQG + Kalman Filter Up to 59% Lower RMSE

05 // CTRL • ROB (MEng CAPSTONE) 2026 • 200-RUN MONTE CARLO

Real-Time LQG Lane-Change Controller

Designed a 100 Hz LQG lateral controller (LQR + discrete Kalman filter) on a 4-state bicycle model tracking a 3.5 m lane change. Validated across 200-run Monte Carlo trials at 40, 80, and 120 km/h, cutting RMSE by up to 59% on a nonlinear Pacejka tyre plant.

STATE ESTIMATION ZOH Joseph-Form Kalman

VALIDATION MATLAB • RK4 • Pacejka Model

ESP32 Home and Plant Health Monitoring IoT Platform

ESP32 • 1,440 Readings/Day Oracle Cloud ARM • nginx

06 // IOT • EMB 2+ MONTHS CONTINUOUS • $0 COST

Home & Plant Health Monitoring Platform

Full-stack IoT platform where ESP32 nodes stream DHT11, BH1750 light, and 4-channel soil-moisture data to a self-hosted Node.js API and SQLite database behind nginx on an Oracle Cloud ARM VM.

SENSORS & EDGE ESP32 • DHT11 • BH1750 • 4× Soil

CLOUD STACK Node.js • SQLite • nginx • OCI

Campus IoT Automation System with 3D-Printed Translucent Enclosure

3D Enclosure • SRM TRPEC ESP32 / ESP8266 • MQTT

07 // IOT • EMB ~20 AUTOMATED SWITCHES & DEVICES

Campus IoT Automation System

Automated ~20 switches and devices for the university using an MQTT network of ESP32/ESP8266 nodes inside 3D-printed switchgear enclosures and a Raspberry Pi gateway, with threshold control and OTA updates.

ENCLOSURE 3D-Printed • Toggle Switches

NETWORK MQTT • ESP32 / ESP8266 • OTA

ShredStock Production Dashboard on Monitor

Galati Cheese Company Zero Stock-Outs

08 // MFG • FULL-STACK GALATI CHEESE COMPANY • PRODUCTION

ShredStock — Manufacturing Inventory Platform

Built ShredStock (React, TypeScript, Node/Express, Prisma/SQLite, JWT role-based access, Oracle Cloud) after a box shortage stopped production; its live dashboard and alerts have delivered zero stock-outs since launch.

IMPACT Zero Material Stock-Outs

STACK React • TS • Prisma/SQLite • OCI

ESP32-CAM and PIR Motion Intruder Alert Hardware

3D-Printed Housing ESP32-CAM • PIR • Antenna

09 // IOT • SECURITY LIVE LOCAL FEED • DETECTION ZONES

Intruder Alert & Surveillance System

Built an ESP32-CAM and Raspberry Pi security system that captures a photo on PIR motion and emails it automatically via SMTP, featuring a live local video feed, configurable detection zones, and scheduled alert suppression.

HARDWARE ESP32-CAM • RPi • PIR Sensor

SOFTWARE Python • SMTP • Zone Masking

PROFESSIONAL TRACK RECORD

Work Experience & Engineering Leadership

From founding Femto 3D and delivering 200+ hardware prototypes to supervising industrial production lines in Windsor and managing 99.9%-uptime global databases at IDP Education.

Feb 2021 – Dec 2024 Thanjavur, India • femto3d.com

EMB ROB IOT 3D PRINTING

Founder & Lead Engineer (Embedded Systems & Product Prototyping)

Femto 3D (femto3d.com)

Delivered 200+ projects for 50+ clients end to end (requirements, Autodesk Fusion 360 CAD, FDM/SLA 3D printing, Embedded C/Python firmware, assembly, QA, and handoff), working with 2 freelancers.
Engineered several prototype iterations of gas-system components for KRT Transport, refining each version against field feedback.
Redesigned stronger replacement fan knobs for Meenakshi Hospital after aftermarket parts kept breaking, ending the repeat replacements.
Built automation prototypes combining servo motors, sensors, and embedded control on Arduino, ESP32, and Raspberry Pi, with MQTT cloud dashboards for remote monitoring.
Calibrated FDM and SLA printers for tight tolerances and verified parts against engineering drawings and GD&T before delivery.

Mar 2025 – Present Windsor, ON, Canada

MFG LEAD AUTOMATION

Shred Line Supervisor (Jul 2026 – Present) & Process Control / Machine Operator (Mar 2025 – Jul 2026)

Galati Cheese Company

Lead a 5-person shred line team producing 6 to 7 tonnes of cheese a day on a 5-day single-shift schedule, with zero lost-time incidents since taking over the line.
Cut changeover time from ~60 minutes to 20–30 minutes (50%+ faster) across 3–4 weekly changeovers by standardizing setup steps and operator training.
Reduced unplanned downtime from bagger film tangling and uneven weights by 80%+ (from a stop every 1–2 hours to 1–2 stops a week) via fault logbooks and targeted preventive maintenance.
Built ShredStock (React, TypeScript, Node/Express, Prisma/SQLite, JWT, Oracle Cloud) after a box shortage stopped production; its low-stock alerts have delivered zero stock-outs since launch.
As Process Control & Machine Operator across 5 machines (3 shredders, 2 packing lines), cut rejected/reworked bags by ~70% (from 20–30 per tonne to 5–10) and restored first-level faults on sensors, motors, solenoid valves, and belts within 5–10 minutes.

Jul 2023 – Nov 2024 Chennai, India

DATA ORACLE / MYSQL AWS RDS

Junior Database Administrator (DBA)

IDP Education (Co-owner of the IELTS English Test)

Maintained 99.9% uptime on the Oracle and MySQL databases behind the global IELTS booking platform.
Optimized SQL and PL/SQL through execution-plan analysis, index tuning, and schema restructuring, cutting a key report query from ~90 seconds to 10 seconds (~89% faster).
Migrated 250,000+ records from on-premise Oracle to Amazon RDS and Amazon Redshift as one of a 6-person team, owning database-side validation and overnight cutover with zero production impact and zero data loss.
Automated daily health checks and alerting with Linux shell scripts and cron, saving ~10 hours a week of manual monitoring.

Jan 2022 – Jan 2023 Tiruchirappalli, India

EMB IOT AI / ML

Tutor — Embedded Systems & IoT Instructor (Marcellotech) & Project Intern (SD Pro Solutions)

Marcellotech (Feb 2022 – Jan 2023) • SD Pro Solutions (Jan 2022)

Taught an embedded curriculum (Embedded C/C++, AVR and ARM Cortex architecture, I2C/SPI/UART interfacing, ESP32/Arduino IoT, motor control) through hands-on firmware and hardware bring-up labs at Marcellotech.
Mentored 40+ students in ~10 project teams of 4, bringing nearly every team to a working hardware project.
At SD Pro Solutions, built a YOLO-based lane detection model feeding steering control for a driver-assist demo, reaching ~90% detection accuracy.

EDUCATION & HONOURS

Academic Excellence & National Innovation Awards

Master of Engineering (MEng), Electrical & Computer Engineering GPA: 9.2 / 10

University of Windsor, Windsor, ON • Jan 2025 – Jun 2026

Coursework: Control Systems Design, Advanced Embedded Systems, Digital Signal Processing, Advanced Energy Storage Systems, Engineering Management.
Capstone: Real-Time LQG Lane-Change Controller • AIRC Lab Volunteer: Pixhawk Surveillance Quadrotor (1 km range).

Bachelor of Engineering (BEng), Electronics & Communication Engineering CGPA: 8.7 / 10 (Distinction)

SRM TRP Engineering College (Anna University), India • Jul 2019 – May 2023

First Class with Distinction • Capstone: BCI-Controlled Bionic Arm (Best Project; TNSI 2022 National Winner).

Honours, Awards & Volunteering

🏆 Winner, TNSI Final 2022 (Government of Tamil Nadu) — INR 1,00,000 grant for BCI Bionic Arm
🥇 1st Place, Project Expo 2022 — SRM TRP Engineering College (BCI Bionic Arm)
🥇 1st Place, CAD Modelling Competition — SRM TRP Engineering College
🥈 Runner-Up, IEEE Region 10 (Asia-Pacific) Undergraduate Project Video Contest 2021
🏅 Finalist, Smart India Hackathon 2020
🤝 STEM Technical Volunteer (2021–2022) — Delivered 5+ hands-on Arduino, IoT & 3D-printing workshops reaching 500+ students

Fabrication, 3D Printing, Robotics & Controls

3D Printing & CAD FDM & SLA • Fusion 360 • AutoCAD • GD&T
Controls & Estimation Simulink • LQR/LQG • Kalman Filter • PID
Simulation & Modelling State-Space • ZOH • RK4 • Monte Carlo • Pacejka
Robotics & Flight Pixhawk 2.4.8 • ArduPilot • 12-DOF Legged Gait
Manufacturing & QA Multivac • Pneumatics • HACCP • GMP • LOTO

Embedded Systems, PCB, IoT & AI/ML

Languages Embedded C • C++ • Python • MATLAB • SQL • TS/JS
Platforms & Sensors ESP32 • ESP8266 • Arduino (Mega/328P) • RPi
Protocols & Bus UART • I2C • SPI • GPIO • PWM • ADC/DAC • MQTT • BLE
PCB & Analog Design Autodesk Eagle • TL074 Op-Amp • Active Filters • EEG/EMG
AI/ML, Cloud & DB TensorFlow • PyTorch • YOLO • XGBoost • Oracle • AWS RDS

CERTIFICATIONS (COURSERA)

3D Model Creation with Autodesk Fusion 360 (Autodesk) • Oracle Database Foundations (LearnQuest) • Introduction to Git & GitHub (Google) • Using Python to Interact with the OS (Google) • Troubleshooting & Debugging Techniques (Google)

WINDSOR, ON • OPEN WORK PERMIT (CANADA)

Let's build reliable hardware, embedded firmware, and intelligent systems.

Available for Embedded Systems, Hardware Prototyping, Robotics/Controls, IoT, and Manufacturing Automation roles across Canada.

✉ [email protected] ☎ +1 437 707 4889 ⌘ github.com/fazil-salam ◈ femto3d.com

Connect on LinkedIn (/in/connectfazil) Email [email protected] ↗