Electrical engineering / hardware design

Pratham Ingale

avionics hardware/power electronics/mixed-signal PCB design/bring-up & validation

spacex

starlink aviation

tesla

cell manufacturing

pratham.ing49@gmail.com704-431-7206LinkedIn
Recovery System PCBResume

Internships

Full resume

SpaceX | Starlink Aviation

Avionics Hardware Design Intern

Summer 2026
Woodinville, WA

  • -Redesigned AC- and DC-path input EMI filters for a 400 W aircraft AC/DC PSU, increasing power capability 38% while addressing magnetic saturation, thermal limits, and filter impedance.
  • -Passed DO-160 current-harmonics requirements and led EMI/EMC validation by authoring the test plan and executing conducted-emissions testing.
  • -Led proton radiation testing of 4 buck-converter designs with no DSEE observed, then owned schematic and PCB layout for 4 follow-up heavy-ion test coupons.
  • -Supported critical-path power and EMI bring-up for a new antenna revision with 15 buck converters, reducing VHF emissions by 15 dB through frequency, mode, stability, and input-filter optimizations.

SpaceX | Starlink Aviation

Avionics Hardware Design Intern

Fall 2025
Woodinville, WA

  • -Designed a 60 W AC/DC isolated half-bridge LLC resonant converter using ZVS to improve efficiency by 15% over the existing flyback.
  • -Tuned the hybrid-hysteretic control loop using AP310 injection to secure phase and gain margin across 10-100% load; owned schematic, PCB layout, and bench bring-up.
  • -Executed staged bring-up of a major 400 W isolated AC/DC PCBA revision across CrCM PFC, LLC, boost, and buck stages with DO-160 current-harmonic validation.
  • -Led RCA for 3 bring-up failures involving a buck-feedback trace, chassis-coupled load-switch noise, and LLC cross-regulation collapse on the auxiliary rail.

Tesla | Cell Manufacturing

Cell Electronics Design Intern

Summer 2025
San Diego, CA

  • -Designed a 4 kW, 50 V / 80 A mixed-signal PCB with 1 Mbps CAN FD, discrete window comparators, automatic CAN termination, hardware addressing, and connector-orientation detection.
  • -Integrated pre-charge, load-switch soft-start, OCP, UV/OV protection, buck and isolated power domains, creepage control, and RLC common-mode filtering.
  • -Engineered an 8-layer, 2 oz high-current PCB rated for 2.5 kW and validated power integrity and thermals at 450 A for 700 s.
  • -Designed a high-speed digital star interface for 1 host and 2 nodes with sub-3 ns edges, controlled impedance, ground-via shielding, capacitive coupling, and damped RLC filtering.

Education

Georgia Tech / B.S. Electrical Engineering

Expected graduation: December 2027. GPA: 4.0.

Skills

Power

Isolated LLC, AC/DC and DC/DC converters, ZVS, loop gain, EMI filters, PFC and harmonic analysis

PCB

Stackup, Impedance Control, Return Paths, Creepage, Current Density, PDN

Mixed Signal

I/V/T sensing, SAR ADCs, anti-aliasing, comparators, discrete voters, SPI, I2C, CAN, Ethernet, USB

Lab

Oscilloscopes, HV/current probes, e-loads, AP310 FRA, PX8000 power analyzer, IR camera, thermal chambers

EDA & Software

Altium Designer, Xpedition Designer, KiCAD, LTspice, SIMPLIS, TINA-TI, VS Code, GitHub, Enovia, Jira, Excel

Resume

Embedded PDF
Download

Projects

All projects

Recovery System

Fault-tolerant recovery avionics with triple-MCU voting and ten high-current deployment channels

A six-layer mixed-signal recovery controller for fault-tolerant rocket parachute deployment. The board combines dual input power paths, four regulated power stages, three independent STM32 control domains, discrete median-voting logic, 4x redundant hardware safing, inertial and environmental sensing, and ten 24 V ignition channels.

Case studyLayout3D

RF Link Evaluation Board

Layout in progress; 2.4 GHz mixed-signal evaluation platform for RF-path characterization, VSWR measurement, and automated telemetry logging

A 2.4 GHz mixed-signal RF evaluation board for characterizing a LoRa telemetry transceiver under controlled transmit, receive, and mismatch conditions. The board combines switched RF test paths, forward and reverse power measurement, detector telemetry, current and temperature sensing, a 12-bit SAR ADC, and Compute Module 5 control and data logging.

Case studyLayout3D

Vespula Avionics Module

Redesign and validation of a 48 V flight engine controller for valve actuation, ignition, and sensor acquisition

A six-layer flight engine controller operating from the vehicle's 48 V avionics bus. The board commands solenoid valves and igniters while acquiring differential sensors, RTDs, and pressure transducers used during engine start and shutdown. After major first-revision faults were found, I owned the electrical and PCB revision, led bring-up, and became the board's day-to-day operational owner.

Case studyLayout3D

Darcy Battery Management System

Protected 12-cell battery interface and monitored power-distribution node for vehicle avionics

A four-layer battery-management and power-distribution PCB connecting a 12-cell lithium-ion pack to the Darcy avionics system. The board combines protected battery input handling, regulated auxiliary power, five controlled load outputs, connector-level load switching, current and voltage telemetry, and current-loop sensor interfacing.

Case studyLayout3D

Contact

pratham.ing49@gmail.com704-431-7206linkedin.com/in/pratham-ingale