Electrical engineering / hardware design

Pratham Ingale

high-speed digital + signal integrity/power electronics/RF + mixed signal/PCB design + bring-up

spacex

starlink aviation

tesla

cell manufacturing

pratham.ing49@gmail.comLinkedInGitHub
Recovery System PCBView resume

Internships

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.

Selected hardware

Projects

A mix of boards I have already built and tested, plus a few systems I am still designing. I keep measured results separate from the stuff that is still just a target.

All projects

Recovery System

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

A six-layer recovery controller built around two power trees, three independent STM32 domains, hardware voting, local sensing, and ten 24 V deployment channels. I owned the board end to end, from architecture and layout through bring-up and the full ten-channel deployment test.

Case studyLayout3D
RF Telemetry System thumbnail

RF Telemetry System

Dual-band LR2021 flight telemetry system for 915 MHz / 2.4 GHz with switched diversity, RF-health telemetry, and hardware fault protection

The dual-band flight radio I am currently designing around one LR2021 and a CM5. It has separate 915 MHz and 2.4 GHz PA/LNA/filter chains, switched antenna diversity, forward/reflected-power sensing, twelve power-monitor channels, and hardware that can shut the RF side down without waiting on Linux.

Case study

Flight Computer

Central flight-compute and black-box avionics board for sensing, storage, telemetry, and recovery coordination

The main compute and data-recording board in the flight stack. I helped review parts of the design, then owned the bring-up side: power characterization, processor/sensor/interface checks, debugging, and keeping the board usable through subsystem and vehicle integration.

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 on the 48 V avionics bus. I inherited this board rather than designing it from scratch, and my revision work focused on the broken interfaces: BeagleBone pin mapping, connector/control/ADC-related routing, bring-up, integration, and validation.

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 board between the 12S pack and the Darcy avionics. I designed the schematic and PCB, ordered and assembled the hardware, then brought up the protected input, five switched outputs, and measurement paths.

Case studyLayout3D

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, high-current layout

Mixed Signal

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

Lab

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

EDA & Software

Altium Designer, Xpedition Designer, KiCad, LTspice, SIMPLIS, TINA-TI, Python, C/C++, Git

Resume

Contact

pratham.ing49@gmail.comlinkedin.com/in/pratham-ingalegithub.com/prathamingale49