Mechanical Engineer - UAV Systems - HMU

Karefyllis Alexandrou

I build fixed-wing UAV concepts, industrial design prototypes, automation rigs, embedded control, and ground-control interfaces.

Raven-01 fixed-wing UAV concept
01 Fixed-wing UAVs
02 Embedded control
03 MPC / CBF safety
04 Python / PyQt GCS
05 Industrial automation
Profile

Engineering portfolio for UAV systems and autonomous aerial robotics.

My work sits between mechanical design, electronics, control, and software. That combination matters in UAV development and industrial automation because the strongest solutions are not isolated parts. They are integrated systems that can be designed, built, tested, and improved.

I have practical industry experience in mechanical design and a technical direction focused on fixed-wing UAVs, industrial product design, safety-critical control, telemetry, and automation workflows.

Selected Work

UAV development areas

Angled render of a fixed-wing UAV concept
Fixed-wing

2 m Class UAV

Conceptual and technical design for modular fixed-wing UAV platforms, including airframe layout, payload integration, and manufacturability constraints.

  • Airframe configuration
  • Payload bay planning
  • Mechanical documentation
Fixed-wing UAV concept used for safety-critical control research
Autonomy

Safety-Critical Control

Research direction using constrained trajectory tracking, Model Predictive Control, and Control Barrier Functions for safer autonomous navigation.

  • MPC trajectory control
  • CBF safety layers
  • Obstacle avoidance research
Topology optimized drone structure render
Optimization

Lightweight Structures

Topology optimization, generative design, 3D printed structures, and stiffness-to-weight improvement for UAV and robotics applications.

  • nTopology workflows
  • CAD and manufacturability
  • Carbon-reinforced concepts
Industrial Design & Automation

Practical mechanical systems that move from CAD to controlled prototypes.

Planetary gearbox assembly Exploded mechanical layout for low-cost robotic arm actuation
Mechanism design

Low-Cost 3D-Printed Planetary Gearbox

A low-cost planetary gearbox designed for 3D printing as a compact torque-multiplication solution for robotic arm joints and prototype automation systems.

  • Designed for additive manufacturing and fast iteration
  • Compact coaxial gear reduction for robotic arm joints
  • Cheap replacement for early-stage commercial gearbox testing
Planetary gearbox Robotic arm 3D printing Actuation
Prototype workflow

Concept to test-ready hardware

01 Concept requirements, sketches, architecture
02 CAD assemblies, enclosures, mechanisms
03 Prototype 3D print, machining, integration
04 Test fixtures, sensors, iteration
Design

Industrial Product Design

CAD assemblies, product housings, brackets, mechanisms, ergonomic layouts, and design-for-manufacturing thinking.

Mechatronics

Automation Systems

Sensors, actuators, motors, microcontrollers, feedback loops, motion control, and repeatable mechanism behavior.

Testing

Engineering Fixtures

Motor thrust stands, servo benches, payload release fixtures, sensor calibration rigs, and lab automation tools.

Delivery

Design Documentation

Technical drawings, BOMs, tolerances, wiring notes, test procedures, and clear engineering reports.

Systems

From airframe to ground station

Layer 01

Airframe

Fixed-wing layout, structures, payload integration, and mechanical constraints.

Layer 02

Embedded

Teensy, STM32, ESP32, sensors, serial buses, and real-time control loops.

Layer 03

Autonomy

MPC trajectory tracking, Control Barrier Functions, and safety constraints.

Layer 04

Ground Station

Python, PyQt, MAVLink telemetry, mission planning, and live status views.

Research Paper

Fixed-wing aerial robotics testbed for safety-critical control.

A technical paper connecting mechanical UAV design with control architecture for autonomous navigation, obstacle avoidance, MPC, and Control Barrier Function research.

Open Paper
Programs

SVK Robotics and Project LUMINA

Contributed to early-stage concept development and proposal formulation for a 10M EUR European Defence Fund project through SVK Robotics.

Represented SVK Robotics at NATO Innovation Days, communicating UAV and autonomous systems direction in a defence innovation environment.

Capabilities

Technical matrix

Industrial Design

Product housings, mechanisms, fixture design, material-aware layouts, and manufacturable assemblies.

Mechanical

SolidWorks, Creo, Inventor, Fusion 360, structural concepts, payload integration.

Control

PID, Model Predictive Control, Control Barrier Functions, safety-critical navigation.

Embedded

Teensy 4.1, STM32, ESP32, Raspberry Pi, sensors, I2C, SPI, UART networks.

Software

Python, PyQt, MAVLink communication, telemetry interfaces, simulation/live modes.

Optimization

nTopology, generative design, 3D printing, carbon reinforcement, lightweight design.

Automation

Sensor-driven mechanisms, motor control, test rigs, calibration tools, and prototype automation.

Documentation

LaTeX, Excel engineering calculations, technical writing, research documentation.

Contact

Available for UAV engineering, research, and systems conversations.