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Hardware Product Designer with 10+ years of experience with consumer products and device design expertise. Have a dual background in Industrial Design and Mechanical Engineering. I have designed more than 80 hardware products from concept to mass manufacturing, working with clients from the USA, UAE, Europe and Asia. I find it meaningful to bring innovative ideas to life through tangible products.🏅Working for over a decade in Industrial Design and Mechanical Engineering, I found my niche in Design for Manufacturing for consumer products industrial design. I worked with international companies, established global design studios, and research facilities for multiple years before starting my full-time design practice. It brings me great fulfilment to see the products I design positively impact lives, making everyday tasks and experiences simpler, making them more efficient and more comfortable. My design language is influenced by Braun's design principles and the work of Braun, especially by Dieter Rams. The majority of my work centres on Consumer Electronics, IoT & Wearables and Medical Devices product design. My expertise lies in creating innovative solutions across diverse industries, including ✅ medical devices, ✅ AI-powered hardware IoT devices, ✅ AI-based wearable devices, ✅ consumer electronics, ✅ healthcare, and more. I helped clients save thousands of dollars in expensive manufacturing mistakes (ex., tooling, electronics, hardware and supply-chain) by optimising the design and setting it up for success. Early consideration of product certification, safety standards, DFM guidelines, safety protocols, and rigorous in-house functional testing before it goes to the factory helps a great deal. I have designed products to generate more than 50x ROI by translating ideas into functional, production-ready designs, which were successfully funded by crowdsourcing, grants, and VC funding, to eventually a full-fledged market launch in different global markets. Along with end-to-end product design and development, I offer strategic consultations that consider key factors such as target markets, user needs, competitive landscape, material selection, and efficient manufacturing processes. This holistic approach ensures the product not only meets design expectations but is optimised for success in the marketplace. Over the years, I’ve built a dynamic small lean team of professionals, including a PCB designer, a firmware programmer, a software developer, and a design engineer, to be able to develop a full product design solution. My team and I handle everything from conceptual design to detailed design for manufacturing (DFM), including industrial design, mechanical engineering, electronics PCB design, firmware programming and testing, and app development, ensuring the product is ready for production at scale. I also support design for manufacturing (DFM) design audits, which can save companies thousands by preventing manufacturing issues. 🏅 My design process is rooted in innovation, seamless functionality, and prototyping at its core. With a dedicated prototyping station and multiple 3D printers at my disposal, I continuously iterate designs to ensure optimal results. This hands-on approach allows for rapid testing and refinement, ensuring that the product is not only visually appealing but also highly functional and manufacturable. Core services include: 🔵 Industrial Design ✅ Ideation & Concept Development ✅ Design for Manufacturing (DFM) & Testing ✅ 3D CAD Modeling & Prototyping ✅ Manufacturing Consultation ✅ Design for Injection Molding Tooling ✅ Patent Drawings & Documentation 🔵 Strategic Product Design Consultation 🔵 End-to-End Product Development & Testing ✅ Proof of Concept Development ✅ Electronics Design & PCB Development ✅ Firmware Programming ✅ Product Concept Design ✅ Design for Manufacturing ✅ Prototype Development & Testing ✅ Manufacturing Consultation If you're looking to bring your product idea to life or need expert guidance through the design and manufacturing process, I'd love to discuss how we can make that happen. Book a 30-minute consultation to explore the possibilities!

I help medical and IoT product teams design the right hardware architecture early, so they avoid costly PCB re-spins, noise issues, and late-stage failures. If you’re building a sensor-heavy, STM32-based, or medical-adjacent product, I act as your hardware systems architect—focusing on design decisions, trade-offs, and long-term reliability, not just execution. How I typically help: • System architecture & feasibility studies • Component and topology selection (MCU, sensors, AFE, power) • Schematic-level hardware design & review • Pre-fabrication PCB audits to reduce redesign risk My work is decision-driven and outcome-focused. I start by understanding what you are building and why, then provide clear, documented recommendations you can confidently execute or manufacture. I’ve worked on medical electronics, bio signal front ends (ECG/EMG), wearables, and IoT devices, where design mistakes are expensive and timelines matter. If you’re looking for clarity, strong architecture, and fewer hardware surprises, I’d be glad to help. ✅ Core Expertise 🔹 Hardware Product Development - Architecture Design, Schematic & Layout (up to 12-layer PCBs) - Rigid, Rigid-Flex & Flex PCB Design - Signal & Power Integrity, EMI/EMC mitigation - DFM/DFT, FMEA, Risk Analysis, Certification Prep - BOM optimization, part lifecycle, obsolescence management 🔹 Sensor-Integrated Wearables & IoT - Real-time biometric sensing (ECG, EMG, HR, SpO2, Temp, IMU) - Wireless: BLE, Wi-Fi, LoRa, 4G, CAN, RS485 - Medical-grade signal acquisition & conditioning - Battery management, power efficiency & charging circuits 🔹 Prototyping & Compliance - Pre-compliance testing: EMI/EMC, Thermal, Vibration - Regulatory: Medical safety (IEC standards), ISO/NABL - Detailed documentation: test plans, architecture diagrams, handover packages 🔹 Tools & Platforms - ECAD: Altium Designer, OrCAD, CAM350, KiCAD - Firmware Platforms: STM32, Nordic nRF52, ESP32/8266, Microchip, Raspberry Pi - Protocols: I2C, UART, SPI, RS232/RS485, LVDS, RF, NFC ✅ Deliverables - Design Concept Block Diagrams - Process Flow Block Diagrams - Schematic PDF - Design Files (Schematic & Layout) - Fabrication Files - Assembly Files - Bill of Materials - 3D Models - Components Library - Test Documents (If req.) 🏆 Notable Projects & Solutions Built - Smart Drug Delivery Device: Precision-controlled insulin injector - Bone Density Meter: Early-diagnosis medical scanner - Julia Robot: Cooking automation system with embedded sensors - EMG Wearable: Portable diagnostic device for muscle activity monitoring - SOWBIT: Veterinary health monitor (ECG, SpO2, Temp) for livestock - Smart Ring: Measures multiple vitals via fingertip contact - Elite Alerte: Maritime emergency alert & sensing system - CloudSwitch: IoT-enabled wireless AC meter for remote energy tracking - Fuel Level Sensor (Ultrasonic + GSM): Real-time monitoring for containers - PoE Switch & Weighing Scale: Industrial-grade, high-precision electronics 🌍 Why Clients Choose Me ✅ Medical-grade design focus with regulatory foresight ✅ Deep cross-industry experience from wearables to industrial controls ✅ Excellent communication, proactive updates, and engineering documentation ✅ Efficient collaboration with global clients and vendors ✅ Quality-first mindset with long-term reliability and support

With over 20 years of experience, I am a seasoned professional in embedded and IoT product development. My expertise spans sensor-based solutions, audio algorithm development, and cloud-based SaaS solutions using AWS, GCP, and Azure. I also have extensive experience with mobile applications, including BLE apps / hardware integration over BLE developed with Flutter, ReactNative, SwiftUI, Kotlin (native development ) too. I began my career as an Audio DSP firmware engineer, specializing in digital signal processing algorithms and filter design for multichannel audio decoders and encoders, building and optimizing them for multiple DSP chipsets. This foundation led me to technical leadership roles within offshore development centers and eventually into leading product development in IoT startups. Of late, I've focused on developing analytical solutions in the smart home, Industry 4.0, and health tech sectors using nRF52, STM32 and ESP32. My key contributions include solution architecting and algorithm design for these cutting-edge applications, including BLE-powered medical device solutions. I am a process-oriented professional with deep knowledge in audio compression, data encoding, DSP Filters and post-processing algorithms. My core technical skills include: - Proficiency in C, C++, Python and Assembly programming for optimizing algorithms on resource-constrained embedded platforms. I'm also well-versed in golang and node.js. - Designing and building cloud-based analytical IoT solutions for enterprise energy management, leveraging multiple services across AWS ( including AWS IoT Core, AWS Greengrass ), GCP, and IBM Cloud. - Extensive knowledge of the BLE stack, having developed mobile applications for diverse IoT solutions and BLE-based medical devices. - Hands on experience with all BLE profiles - LE Coded PHY, 1M, indoor positioning using Beacons, AoA etc. - Experience with MQTT-based solutions, including hardware - firmware integration, integration of the solution with custom cloud platforms and GCP / AWS IoT Core. - Experience building multiple medtech / healthcare solutions - involving hardware / firmware / mobile application integrated over Bluetooth ( BLE ) and cloud applications adhering to HIPAA. Also worked with FDA / 510(k) compliance processes. - Proficiency in LoRa technology, having built embedded applications for IoT solutions primarily using LoRa EU and US frequencies. My background in developing regulated medical devices and health tech solutions makes me the ideal candidate for your project. I have extensive experience architecting and implementing secure, HIPAA-compliant solutions that integrate hardware, firmware, and mobile applications over BLE. I've successfully navigated the complexities of FDA and 510(k) compliance processes, ensuring not only technical excellence but also regulatory adherence. My skills include developing robust BLE-based medical device solutions, building analytical cloud platforms, and optimizing firmware for performance and reliability. I can offer both the deep technical skills and the critical regulatory knowledge required to bring your innovative medical product to market safely and effectively. As a specialist in wireless communication protocols for IoT, I can provide the targeted expertise you need for your project. My extensive hands-on experience with the entire BLE stack—including AoA, LE Coded PHY, and indoor positioning with Beacons—allows me to tackle even the most complex integration challenges. I've developed numerous mobile applications that seamlessly integrate with BLE hardware, ensuring a smooth and reliable user experience. I am also highly proficient in LoRa technology, having built complete embedded applications for EU and US frequencies. Whether you need to optimize a high-performance BLE application or build a long-range LoRa network, I have the in-depth knowledge to deliver a top-tier solution. As you can see, I have over a decade of experience in leadership roles, having led cross-functional offshore teams, including managing groups of 20 or more engineers and QA professionals. I'm eager to take up the next Upwork project and contribute my skills / experience to a highly competitive team.

I’m Avi Gupta, an electronics and PCB design expert with 11+ years of experience and 500+ boards designed for IoT, industrial, medical and consumer products. I help startups and product companies turn ideas into production-ready hardware using Altium Designer and other industry tools. ✅What you actually get when you work with me • Boards that are designed to pass EMI/EMC, not just “hope for the best” • Architecture and layout decisions that reduce respins and save months • Clear, production-ready documentation your manufacturer will thank you for ✅I’m most useful to you if: • You have a concept or early prototype (ESP32, STM32, or similar) and need it turned into a robust, production-ready Altium design. • You already have a board that “sort of” works and you’re worried about noise, reliability, thermal issues, or compliance. • You need an experienced hardware mind to own the electronics while your internal team focuses on firmware, apps, or business. ✅What I can help you with 1. New product hardware design (concept to production-ready PCB) • Architecture and block diagrams for your electronics (MCU, power, interfaces, connectivity) • Schematic design and capture in Altium Designer (or KiCad/Eagle on request) • Multilayer PCB layout with controlled impedance, length matching, and proper grounding • Design for manufacturability (DFM) so your CM can build and test boards smoothly 2. PCB review, cost-down and reliability upgrade Already have a design? I can: • Review your schematic and PCB layout for signal integrity, power integrity, and EMI/EMC risks • Reduce BOM and PCB cost (alternative components, better stack-up, optimized routing) • Improve thermal behavior and reliability for 24/7 operation in real environments • Help you move from “prototype that works on the bench” to “design that works in production” 3. Compliance-conscious, production-focused design • Design practices aligned with EMI/EMC, CE, UL and CISPR requirements • Grounding, filtering, shielding and layout strategies to avoid surprises in the test lab • Clean documentation: schematics, PCB files, Gerbers, fabrication/assembly outputs, PDFs, BOMs ✅Recent project highlights • Designed an ESP32-based LoRa IoT sensor node with RS485/Modbus interface for industrial monitoring. Created a 4-layer Altium PCB optimized for low power, robust EMC behavior, and easy enclosure integration. • Developed an STM32-based industrial controller board with isolated digital inputs/outputs, 24 V power domains, and RS485/CAN communication. The hardware was taken from concept to tested prototype and prepared for volume manufacturing. • Reviewed and cost-optimized an existing ESP32 control board, replacing hard-to-source parts, simplifying the power stage, and reducing BOM cost by ~25% while improving thermal margins and layout quality. • Designed a Raspberry Pi-compatible expansion HAT with LoRa communication, environmental sensing, relay output and RGB indication. Delivered complete Altium design, manufacturing files, and test guidance for small-batch production. • Created a high-voltage/power PCB with isolated gate drivers, current sensing, and careful creepage/clearance management. Layout was done with EMI/EMC and safety in mind to support future certification. ✅Tools, technologies and platforms • Primary CAD: Altium Designer (main tool for professional work) • Also experienced with: KiCad, Eagle, EasyEDA, Proteus • MCUs: ESP32, ESP8266, STM32, NXP, TI and similar 32-bit controllers • Interfaces: RS485, Modbus, CAN, Ethernet, SPI, I2C, UART, USB • Wireless: Wi-Fi, BLE, LoRa (module-based designs) • Applications: IoT devices, industrial controllers, sensor boards, data loggers, power electronics, battery-powered products ✅How I work • Hardware-first mindset: I focus on solid electronics architecture and PCB design; I can support basic firmware bring-up and collaborate closely with your firmware/software team. • Clear communication: upfront questions, regular updates, and intermediate design reviews so there are no surprises. • Production thinking: I design as if your board will go to manufacturing – even if you’re only building 5–10 units today. If you need a reliable hardware partner to design, review or optimize your PCB for a real product (not just a one-off hobby build), send me a message with a short description of your project, current status, and timeline. Let’s see how we can get your hardware ready for the field.

Looking to clearly explain your AI or SaaS product, boost conversions, and stand out in a competitive market? I'm a full-service SaaS video specialist, helping tech startups turn complex ideas into clear, engaging, and high-converting videos. I specialize in working with AI and SaaS companies to create: 🎯 Product Marketing Videos – Capture attention and drive sign-ups 📦 Explainer Videos – Simplify your product’s value in seconds 🚀 Launch Videos – Announce new features with flair 📚 Tutorial Videos – Educate users with professional walkthroughs 🤖 AI-Powered Videos – Leverage Synthesia & other tools for next-gen content Let’s create a SaaS video that not only looks great — but works great. 📩 Send me a message to discuss your project — I’ll help you bring it to life from script to final delivery.

Struggling to prototype reliable IoT devices or scale PCB designs for global brands? As a Senior Embedded & PCB Engineer with 11+ years, I deliver turnkey hardware/firmware solutions—deployed in 10K+ units for hearing aids and 6K+ retail stores. Let's transform your innovative ideas into market-ready products with rapid prototyping and FCC/CE compliance. Services: 1) PCB layout & schematic design using Altium/Eagle for consumer electronics and smart devices. 2) Embedded firmware development in C/C++ for microcontrollers (ARM, AVR) in IoT and wireless systems. 3) Full-cycle prototyping, testing, and regulatory compliance (EMC, safety standards) for startups and brands. 4) Hardware integration for audio, sensors, and Bluetooth-enabled products.