All Case Studies/Aerospace / High-Reliability Engineering
PORTFOLIO CASE STUDYAerospace / High-Reliability EngineeringDomain: Edge Autonomous Flight & Sensor FusionEngagement: Autonomous Systems Engineering Pod

Enabling UAV Navigation at the Edge

Specialized Engineering Scope & Mission Challenge

An autonomous unmanned aerial vehicle (UAV) defense program needed to achieve GPS-denied navigation and real-time obstacle avoidance on compute-constrained edge hardware. During high-velocity tactical maneuvers and electronic warfare jamming, satellite navigation drops out, requiring millisecond-level sensor fusion between inertial measurement units (IMU), visual odometry, and LiDAR. Legacy prototypes suffered from thermal throttling on embedded SoCs and unbounded latency in sensor packet decoding, leading to trajectory drift and mission abortion.

Granular Competency & Technical Requirement Matrix

Embedded C++ Real-Time Deterministic Programming
Extended Kalman Filter (EKF) Sensor Fusion (GNSS/IMU/Visual)
Real-Time Operating System (FreeRTOS / VxWorks) Integration
Hardware-in-the-Loop (HIL) Flight Dynamics Simulation
High-Speed Serial & SPI Sensor Driver Optimization
SWaP-C (Size, Weight, Power, and Cost) Compute Profiling

Critical Engineering & Integration Complexities

  • Deterministic sensor fusion loop requirement under 10ms with zero allowable queue dropouts during abrupt GPS outages.
  • Tight thermal envelope of edge compute modules inside sealed carbon-fiber airframes causing CPU throttling.
  • Asynchronous phase jitter between high-rate IMU (1 kHz) and camera visual odometry (30 fps) causing state divergence.
  • Verification of complex fail-safe fallbacks (dead-reckoning, return-to-base) across dynamic simulated wind shear.

Engineered Delivery & Execution Workflow

01

Compute & Sensor Profiling

Benchmarked latency bottlenecks in sensor ingestion across SPI, UART, and MIPI CSI buses on the target embedded SoC.

02

EKF Core Optimization

Rewrote the extended Kalman filter state-estimation pipeline in cache-optimized, zero-allocation C++.

03

Preemptive Task Partitioning

Configured RTOS prioritisation, assigning dedicated core affinity and DMA buffers to critical IMU feeds.

04

Simulated GPS Jamming Scenarios

Built an automated HIL test environment simulating abrupt satellite loss and dynamic sensor spoofing.

05

Thermal & Power Profiling

Tuned DVFS (dynamic voltage/frequency scaling) policies to eliminate thermal throttling under maximum flight loads.

06

Telemetry & Blackbox Logging

Engineered a deterministic circular buffer logging full state vectors to high-speed NVMe flash.

07

Flight Dynamics Sign-Off

Validated autonomous trajectory adherence across 200+ hardware-in-the-loop stress profiles.

Production Toolchains, Protocols & Frameworks

Embedded C++RTOSGNSS / IMU fusionHardware-in-the-loopFreeRTOSVector DaVinci

06 | PROJECT TARGETS

Project Targets and Business Impact

<50 ms
Edge decision latency target
Target for this engagement.
99.9%
Telemetry completeness target
Target for this engagement.
2.5x
Scenario replay coverage target
Target for this engagement.
-40%
Test-bench setup time target
Target for this engagement.
Business Impact Statement: The workflow makes timing, degraded-mode behavior, and mission-data integrity easier to review before integration, enabling reliable autonomous flight in contested environments.

Customer Confidentiality Note: Customer identity, proprietary codebases, and commercial program specifics have been anonymized in accordance with non-disclosure agreements.