Engineering Portfolio

Andrew Malaty

R&D Engineer • Embedded Systems • Hardware Prototyping

I design and build smart hardware systems that solve real-world problems combining embedded software, electronics, and hands-on validation.

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01

About Me

I'm a research and development engineer focused on building practical, real-world systems at the intersection of hardware and software.

I enjoy taking ideas from concept to working prototype, designing circuits, writing embedded code, and validating performance with real measurements. My work often involves integrating sensors, microcontrollers, and user interfaces into cohesive systems that actually get used.

I'm especially interested in embedded systems, automation, and developing tools that improve how people interact with physical devices.

How I Think

I approach engineering as a hands-on process.

I believe the fastest way to understand a system is to build it, test it, and iterate. I focus on creating working prototypes early, then refining them through measurement and validation.

I'm particularly interested in bridging the gap between hardware and software, making systems that are not just functional, but reliable and intuitive to use.

02

Projects

Coffee Brewing Scale

Arduino Nano HX711 SSD1306 U8g2
Problem

Precision and timing are critical for brewing coffee, but most scales lack intuitive workflows.

Solution

Built a custom Arduino-based scale with an integrated timer and minimal interface.

Key Features

  • Real-time mass display with synchronized updates
  • Integrated timer with simple button control
  • Long-press tare, short-press timer logic
  • Clean OLED interface

What I Learned

  • Designing intuitive user interactions with minimal inputs
  • Synchronizing sensor readings with UI updates
  • Handling debouncing and timing logic cleanly

Cost-Saving Manufacturing Tool Design

3D Printing CAD Design Manufacturing Certification
Problem

Industrial equipment required expensive modifications to meet Intertek safety certification criteria, adding $200+ per unit to manufacturing costs.

Solution

Designed a 3D-printed tool costing $0.20 to manufacture that satisfied Intertek certification requirements, eliminating the need for costly alternative solutions.

Impact

  • Enabled Intertek certification compliance
  • Saved $200 per unit across 2,000 annual units = $400,000/year
  • 99.9% cost reduction while maintaining safety standards
  • Production-ready solution deployed at scale

What I Learned

  • Navigating certification and compliance requirements
  • Designing cost-effective solutions under regulatory constraints
  • Scaling 3D-printed parts for production volumes

ESP32 GPIO Viewer & Control

ESP32 Web Server GPIO Control Wi-Fi
Problem

Debugging and controlling ESP32 GPIO pins typically requires physical access to the device or clunky serial monitoring, making remote development and testing difficult.

Solution

Built a web-based GPIO viewer and controller that runs directly on the ESP32, allowing real-time pin monitoring and control from any device on the network.

Key Features

  • Real-time GPIO pin state visualization
  • Can be integrated in any other project with just a few lines of code and minimal ROM utilisation
  • Remote control of digital pins via web interface
  • Dual mode: Connect to existing Wi-Fi or create standalone access point
  • Live pin reading and writing without serial connection

What I Learned

  • Building responsive web servers on resource-constrained microcontrollers
  • Managing Wi-Fi connectivity modes and network fallback strategies
  • Creating intuitive interfaces for hardware control and debugging

Print Farm Setup & Optimization

3D Printing Consulting Troubleshooting Production
Problem

A Montreal-based golf simulator manufacturer needed help setting up their production print farm and diagnosing ongoing print quality and reliability issues.

Solution

Consulted on print farm setup, diagnosed production bottlenecks, optimized printer configurations, and implemented quality control processes for consistent output at scale.

Key Contributions

  • Configured multi-printer production workflow
  • Diagnosed and resolved print quality issues affecting production
  • Optimized material selection and print settings for specific parts
  • Implemented quality control and testing procedures

What I Learned

  • Scaling 3D printing from prototype to production volumes
  • Troubleshooting complex multi-printer systems
  • Balancing quality, speed, and cost in manufacturing

Smart Filament Dry Box

ESP32 HX711 C++ Web UI
Problem

3D printing filament is highly sensitive to humidity, which affects print quality and consistency.

Solution

Designed a smart dry box using an ESP32 to monitor and display real-time environmental conditions and filament usage.

Key Features

  • Live temperature and humidity monitoring
  • Spool weight tracking using a load cell
  • Web interface hosted directly on the ESP32
  • Wi-Fi fallback access point for easy setup

What I Learned

  • Designing reliable sensor systems
  • Handling real-time data in embedded environments
  • Building user-friendly interfaces on constrained hardware

Keyboard Latency Tester

Logic Analyzer Oscilloscope Testing
Problem

Measuring input latency accurately requires precise timing validation.

Solution

Developed a testing setup using instrumentation tools to measure and verify latency.

Key Features

  • High-resolution timing measurements
  • Signal validation using external tools
  • Repeatable and accurate testing setup

What I Learned

  • Validating real-world timing constraints
  • Using instrumentation to debug and verify systems
  • Building reliable test methodologies
03

Skills & Tools

Embedded & Hardware

  • Arduino, ESP32
  • Sensor integration (load cells, temperature, humidity)
  • Prototyping and system design
  • PCB Design

3D Printing & Manufacturing

  • Production-scale 3D printing and print farm setup
  • Manufacturing consulting and process optimization
  • Material selection and certification compliance
  • CAD design (Fusion 360, Autodesk Inventor, Blender)

Software & Programming

  • C++ (self-taught)
  • Python (self-taught)
  • Embedded firmware development
  • Web development and IoT

Tools & Instrumentation

  • Oscilloscope
  • Logic analyzer
  • Hardware debugging and validation
  • Manual mechanical and electrical test equipment
04

Experience

Research & Development Engineer

Multinational Industrial HVAC Manufacturer • Montreal
  • Develop new product features for industrial dehumidification systems
  • Design and prototype hardware and control systems
  • Test and validate performance using real-world measurements
  • Collaborate across engineering disciplines to bring products to market
05

Get In Touch

If you'd like to collaborate or have a project in mind, feel free to reach out.

✉ Andrew_Malaty@hotmail.com in LinkedIn { } GitHub 🔧 MakerWorld

Let's build something interesting together.