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khossam963-png/README.md

Karim Hossam

Electrical & Electronic Engineer. B.Eng First Class Honours, Coventry University 2026. Based in New Cairo, Egypt.

I design hardware and I ship software. Mains-powered 4-layer PCBs with real isolation barriers and RF sections on one side; a real-time offline voice product with 53 releases behind it on the other. This page is the index.

LinkedIn · Available for freelance PCB design, schematic capture, layout, and design review before fabrication.


Selected work

Project What it is State
UWB Man-Down Safety System Warehouse localisation and fall detection. 4-layer mains-powered anchor, ESP32-S3 + DWM3000, DS-TWR with an NLOS filter and a particle filter. ±20 cm at 43 m. Built, measured
LoRaWAN Mains Energy Meter Class 1 single-phase meter, self-powered from the mains it measures. ADE7953 + STM32WLE5, reinforced 8 mm isolation, 868 MHz. Complete
Industrial IIoT Sensor Node 24 V field node — 4–20 mA loops, opto inputs, relay, isolated RS-485 to a PLC. ESP32-C6, 50 Ω RF feed. Complete, fab package
Industrial Edge Gateway STM32H743, 32 MB SDRAM on a matched parallel bus, 100M Ethernet, isolated RS-485, CAN-FD. In progress
WILCO Offline AI radio crew for DCS World — ATC, AWACS and JTAC over SRS. 102 intents, 33 ms decision time, 53 releases. Shipping

UWB anchor board LoRaWAN energy meter
UWB anchor — 4 layers, 100 mm circular, mains-fed through a 3 kV isolated converter, 10 mm antenna keep-out through every layer. LoRaWAN energy meter — 230 V AC, 63 A CT, reinforced isolation with a routed slot, 868 MHz front end on the safe side.
IIoT sensor node Industrial edge gateway
IIoT sensor node — 8 mm isolation barrier with slots routed through the board, two 4–20 mA loops, isolated RS-485. Edge gateway — LQFP144 at 0.5 mm pitch, 39-net matched SDRAM bus, two 100 Ω pairs. In progress.

What I do

Hardware. Schematic capture and PCB layout in KiCad and Altium. Mains-side design and safety — creepage and clearance to IEC 60664-1 and IPC-2221, reinforced isolation, fusing and surge protection. Switching supplies. Mixed-signal front ends. Controlled-impedance RF, antenna keep-outs and via fencing. Complete manufacturing packages: Gerbers, drill, pick-and-place, assembly drawing, BOM with a real MPN against every fitted part, and a fab README stating the things a board silently depends on.

Embedded. ESP32-S3 and ESP32-C6, STM32 (H7, WL), firmware for two-way ranging, TDMA scheduling, OTA, NVS provisioning, and sensor DSP.

Applied AI and software. Real-time speech to intent to speech, offline. Deterministic intent engines rather than generative guessing. Test strategy at scale — million-utterance evaluation suites, load testing, end-to-end simulation. Cloudflare Workers backends with authentication and 2FA, and a Next.js site in front of them.

How I work

I verify rather than assert. Every number on these pages was measured from the file or the bench, not estimated — board statistics come from the design file, ranging accuracy comes from ground-truth trials, and where something is unfinished or unmeasured it is labelled that way.

The habit came from being wrong in ways that looked right. An isolation barrier drawn to 8 mm that was doing nothing because one component faced the wrong way. A creepage figure of 7.10 mm that was measured along the wrong axis of the package and was really 4.08 mm. Those are written up in full in the project pages, because the mistake is the useful part.


Contact

LinkedIn

Popular repositories Loading

  1. wilco wilco Public

    WILCO - your AI radio crew for DCS World. ATC / AWACS / JTAC over SRS.

    HTML

  2. uwb-man-down-safety-system uwb-man-down-safety-system Public

    UWB indoor localisation and man-down safety for warehouses. 4-layer mains-powered ESP32-S3 + DWM3000 anchor, DS-TWR with NLOS filtering and a particle filter. Measured +/-20 cm at 43 m.

  3. lorawan-energy-meter lorawan-energy-meter Public

    Class 1 single-phase LoRaWAN energy meter, self-powered from the mains it measures. ADE7953 + STM32WLE5, reinforced 8 mm isolation, 868 MHz. 4-layer KiCad design.

  4. industrial-iiot-sensor-node industrial-iiot-sensor-node Public

    4-layer industrial IIoT sensor node. 24 V field power, 2 x 4-20 mA loops, opto inputs, relay out, galvanically isolated RS-485 to a PLC, ESP32-C6 with a 50 ohm RF feed.

  5. industrial-edge-gateway industrial-edge-gateway Public

    DIN-rail industrial edge gateway. STM32H743, 32 MB SDRAM on a matched parallel bus, 100M Ethernet, isolated RS-485, CAN-FD, relay outputs. Work in progress.

  6. khossam963-png khossam963-png Public

    Profile README - index of hardware and software work