MSMohan Sai Potnuru
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Open to embedded, RTOS, IoT & VLSI roles Visakhapatnam, India

Hi, I'm Mohan Sai.

Embedded Systems & IoT Engineer · RTOS · RISC-V / ASIC Physical Design

I take ideas from the transistor to the cloud: register-level firmware, analysed real-time task sets, connected IoT devices and RISC-V silicon. Everything I publish ships with tests, CI and real documentation.

datasheet → registers → drivers → RTOS tasks → protocols → dashboard → GDSII
View projects GitHub LinkedIn
9
PVT/RC corners, warning-free signoff (RISC-V SoC)
24k+
unit-test checks, FreeRTOS project (ASan/UBSan)
0 B
heap in the RTOS firmware: fully static
µs
edge-timing resolution on bare-metal STM32
50+
embedded & IoT prototypes built at CEMS
30+
certifications: Cisco, NPTEL, NIELIT, ISRO...
// full-stack electronics

From silicon to the cloud

I work across the whole ECE stack, and every layer below links to a project that proves it.

L0 · silicon

Digital design & VLSI

Verilog SoC integration, self-checking testbenches, synthesis, floorplan, CTS, routing, multi-corner STA, DRC / LVS / antenna signoff.

RISC-V SoC on SKY130 →
L1 · bare metal

Register-level firmware

Cortex-M4 drivers without HAL, timer input capture, ISR→task deferral, CRC-protected wear-levelled flash, fault capture.

IRSense →
L2 · real time

RTOS & scheduling

FreeRTOS task-set design, rate-monotonic priorities, response-time analysis, mutexes with priority inheritance, watchdog supervision.

rtos-condition-monitor →
L3 · connectivity

IoT & protocols

ESP32 Wi-Fi and MQTT, web dashboards, RFID, energy metering, BLE, 4G LTE / GPS, UART, SPI, I²C, 1-Wire.

Smart Home · DRE-MachGuard
L4 · platform

Embedded Linux

Yocto-based Microchip SAMA5D2 bring-up; GPIO, ADC, PWM, SPI and Wi-Fi from user space with libmraa.

RuggedBoard-A5D2X →
L5 · data

Edge data & ML

Integer DSP on-device (EMA, windowed RMS), and leakage-free scikit-learn pipelines for sensor time series.

AQI Prediction →
// selected work

Projects

Each project is built to the same bar: measured, tested, documented and reproducible.

FreeRTOS · STM32F401Flagship

rtos-condition-monitor

A FreeRTOS V11 condition-monitoring node for the NUCLEO-F401RE, written like production firmware. It samples an analog sensor at 100 Hz, computes a 1 s AC-RMS, raises hysteresis alarms and streams CRC-protected telemetry.

  • Analysed task set: exact response-time analysis runs at boot, with budgeted or measured WCETs
  • Zero heap: every kernel object is statically allocated
  • Watchdog that proves liveness: a supervisor feeds the IWDG only while every task checks in
  • Post-mortem: fault records survive reset; crash injects each fault
  • CI: host tests (ASan/UBSan, gcc + clang), cppcheck and a QEMU boot test on every push
5 tasksU = 14.08% 30 KB flash · 18 KB RAM24,433 checks
Response-time analysis computed by the firmware at boot
taskprioT µsC µsR µs
tmr_svc61000002020
supervisor5500000300320
sensor410000150470
process310000150670
telemetry2100000100011920
cli15000050006620
RTA: PASS, all deadlines met
C11FreeRTOS V11Cortex-M4FCMSIS (no HAL)COBS + CRC-16QEMUGitHub Actions
Source & docs →Architecture →
ASIC · SkyWater 130 nmRTL → GDSII

32-bit RISC-V SoC with 9-corner signoff

A PicoRV32 RV32I core with a 256-byte boot ROM and a custom memory-mapped 8N1 UART, hardened with LibreLane / OpenROAD on the open SKY130 PDK.

  • Verification: a self-checking Icarus testbench boots the SoC from ROM and decodes the serial output in CI
  • Closure: the first run failed placement at 82% utilisation. Die resize, cell exclusions, wire-length limits, slew margins and CTS tuning followed
  • Signoff: zero DRC, LVS-clean, zero antenna; setup, hold, slew, cap and fanout clean across all 9 corners
  • Release: GDS, metrics.json and signoff reports published
500×500 µm die40 MHz target9/9 corners clean
sky130 die · 500 × 500 µm PicoRV32 RV32I decode Boot ROM 0x0000_0000 UART 8N1 0x0200_0000 tx_out →
VerilogYosysOpenROADLibreLaneMagic · KLayout · NetgenMulti-corner STA
Source & signoff reports →
Bare metal · Cortex-M4

IRSense: IR counter & conveyor monitor

STM32F401 firmware that turns an IR obstacle sensor into a measurement instrument for conveyor lines.

  • TIM2 captured in the EXTI ISR: µs timestamps; the glitch filter adds latency, not error
  • Counter, monitor and guard modes; latched JAM, RATE (hysteresis) and INTRUSION alarms
  • Wear-levelled, power-fail-safe flash config with CRC-32 (2,520 saves per erase)
  • 21-command CLI, IWDG, reset-cause reporting
45 host unit testsv1.0.0 release
CSTM32ASan/UBSan CI
Source →
ESP32 · Offline-first🏆 Top 6 + prize

DRE-MachGuard: machinery fault monitor

Built by Team INVENTORS for the DRE Enterprise Hackathon '26 (PS08: offline fault diagnostics on a fault-injectable rig) for machines at remote sites with no internet.

  • DS18B20 temperature, supply-voltage, current-sensor and vibration-event monitoring
  • Rule-based diagnostics on the device; no cloud needed for core functions
  • OLED status display plus three-colour LED condition alerts
ESP321-WireCondition monitoring
ESP32 · MQTT

ESP32 smart-home automation node

Modular firmware with a single non-blocking loop and a rule engine.

  • BME280, BH1750, MQ-2 / MQ-5 gas, water level and PIR sensing
  • RFID lock with roles, lockout and auto-relock; arm/disarm stored in NVS
  • PZEM-004T energy metering, MQTT with retained state, web dashboard + JSON API
  • Manual override buttons keep working when Wi-Fi is down
CI on 2 ESP32 cores
C++MQTTRFIDarduino-cli
Source →
Embedded Linux · Yocto

I/O on RuggedBoard-A5D2X (SAMA5D2)

Step-by-step guides and Python examples for driving hardware from user space on an industrial Cortex-A5 board.

  • Yocto 2.5 BSP, U-Boot 2018.07, Linux 4.9, libmraa v2.0.0
  • GPIO, ADC, PWM, an SPI loop-back self-test, and Wi-Fi via wpa_supplicant
PythonlibmraaYocto
Source →
ML · scikit-learn🏅 Top 40 nationally

AQI prediction for 26 Indian cities

An AICTE × Shell Skills4Future project: daily Air Quality Index prediction (2015–2020) with leakage-free pipelines and a comparison of five models.

Random Forest test R² 0.91
Pythonpandasscikit-learnJupyter
Source →
Power · RenewableTeam lead

Solar-powered EV charging station

Diploma final-year project that I led: circuit design, energy management and renewable-energy integration applied to EV charging. It grew into teaching EV batteries, BMS, motors and charging as a workshop resource person.

Power electronicsSolar PVEV
// evidence, not adjectives

Engineering data

Real numbers from my own build artefacts: the LibreLane signoff metrics of the RISC-V SoC (release v2.1) and the FreeRTOS schedule computed from the firmware's task table. Hover any mark for exact values; every chart also has a data table.

0
DRC errors (Magic) · LVS errors · antenna violations
+7.26 ns
worst setup slack across 9 corners (25 ns clock)
+34 ps
worst hold slack (ff · −40 °C · 1.95 V)
13,481
standard cells at 52.7 % utilisation

Setup slack by PVT/RC corner

Positive = timing met. Dashed line: zero slack. Clock period 25 ns.

Data table

Hold slack by PVT/RC corner

The fast corners are the hold-critical ones: hold buffers (1,361 inserted) keep them positive.

Data table

Detailed-routing DRC convergence

Violations after each TritonRoute iteration: 466 → 0.

Data table

Standard-cell mix

13,481 cells, excluding 32,443 filler cells. Repair buffers come from slew, cap, fanout and hold fixing.

Data table

FreeRTOS schedule at the critical instant

Every task released at t = 0, the worst case response-time analysis bounds. Higher priority preempts lower; ◆ marks each task's completion (its response time). The second sensor/process release appears at 10 ms.

Simulated at 1 µs resolution from the task table in app_tasks.c using budgeted WCETs. The firmware's RTA adds mutex blocking on top (process +50 µs, telemetry +10 ms), giving 670 µs and 11,920 µs, still inside 10 ms and 100 ms deadlines.
Data table
// experience

Where I've worked & trained

Embedded Systems & IoT Engineer (Intern)

Kaumodaki NexusGrid · Visakhapatnam
Apr 2026 – present
  • ESP32 and ESP32-CAM firmware: sensor acquisition, Wi-Fi and MQTT connectivity, cloud dashboards
  • Gas and air-quality analog front-end boards in KiCad; 4G LTE + GPS trackers; BLE load cells and health-monitoring hardware
  • Represented the company at IoT Summit '26 (sponsor delegate) and the Future Skills Summit & Awards 2026, T-Works Hyderabad

Full Stack Python & Agentic AI Intern

CSC India · APSCHE Student Internship
May 2026 – Sep 2026
  • Python full-stack development and agentic-AI frameworks

RTOS Intern: Real-Time Operating Systems

CSC India · APSCHE · IGIAT
May 2025 – Jun 2025
  • Preemptive scheduling, task design, queues, semaphores, mutexes, timers and ISR handling on microcontroller platforms

AI & Data Analytics Intern (Skills4Future)

Edunet Foundation · AICTE · Shell India
Feb 2025 – Mar 2025
  • AQI prediction project, selected among the Top 40 nationally

Space & AI Internship Programs

Agnirva (AICTE recognised)
Jan 2025 – Jun 2025
  • Satellite systems and space-mission fundamentals (80 h, 440+ learning steps), then applied generative-AI tooling

Embedded Systems & IoT Developer (Industrial Training)

Centre of Excellence in Maritime & Shipbuilding (CEMS)
Jun 2023 – Nov 2023
  • Designed, built and tested 50+ real-time embedded and IoT projects on Arduino UNO and NodeMCU (ESP8266); circuit design, PCB development and power management
// recognition & leadership

Achievements & leadership

🏆

Top 6 Finalist + prize

DRE Enterprise Hackathon '26 with DRE-MachGuard (Team INVENTORS)

Oct 2026
🛰️

Lead Support, NASA Space Apps

NASA International Space Apps Challenge, Visakhapatnam local event

2025 & 2026
📡

Chairperson, IETE Student Forum

Leading the forum's technical community and student engagement at DLBCE

current
⚡

Resource Person, EV Technology

3-day workshop at DIET with APSSDC: EV batteries, BMS, motors and controllers, AC/DC charging, diagnostics

Sep 2026
🏅

Top 40 project nationally

AICTE × Shell India Skills4Future: AQI prediction

Mar 2025
🎤

Stage II, Viksit Bharat Young Leaders Dialogue

MY Bharat, Ministry of Youth Affairs & Sports; state-level round

2026
🎪

Main Student Coordinator, Technotsav

ECE technical fest

DLBCE
🤝

Industry–academia FDP

Automation, Digital Twin, Industry 4.0 and Private 5G at GIET University, with BSNL and Kaumodaki NexusGrid

Jun 2026
🎓

NPTEL Elite

Sensors and Actuators: 12-week course, assignments 25/25

Apr 2026
// toolbox

Skills

Languages

C (C11)C++PythonVerilogARM Thumb asm

MCUs, SoCs & boards

STM32 (Cortex-M4F)ESP32 / ESP32-CAMArduinoNodeMCUSAMA5D2RISC-VRaspberry Pi

Real-time & OS

FreeRTOSBare metal / CMSISResponse-time analysisYocto Linuxlibmraa

Protocols & connectivity

UARTSPII²C1-WireMQTTWi-FiBLE4G LTE / GPSCOBS / CRC

EDA & VLSI

YosysOpenROADLibreLane / OpenLaneMagicKLayoutNetgenIcarus VerilogSKY130KiCad

Quality & tooling

Unit testingASan / UBSancppcheckQEMUGitHub ActionsSTM32CubeIDEPlatformIOscikit-learn
// certifications

Certifications

  • Sensors and Actuators (Elite)NPTEL
    2026
  • Foundational Course on Applied Machine Learning & AIConfederation of Indian Industry (INDIAai)
    2026
  • Digital Maturity Diagnostic Framework (DX-EDGE)CII · NITI Aayog · AICTE
    2026
  • MongoDB Basics for StudentsMongoDB
    2026
  • Introduction to IoT · IoT and Digital TransformationCisco Networking Academy
    2025
  • Essentials Automation CertificationAutomation Anywhere
    2025
  • Agentblazer ChampionSalesforce
    2025
  • Marine Electronics: Resistance and BatteriesAlison
    2024

30+ certifications in total, including Cisco, NIELIT, ISRO, TCS iON, Coursera and Great Learning. Full list on LinkedIn.

// education

Education

B.Tech, Electronics & Communication Engineering

Dr. Lankapalli Bullayya College of Engineering, Visakhapatnam
2024 – 2027

Diploma, Electronics & Communication Engineering (82%)

Sanketika Polytechnic College · SBTET Andhra Pradesh
– 2023
// contact

Let's build something that works on real hardware

Open to embedded firmware, RTOS, IoT and VLSI / physical-design roles and collaborations. The fastest way to reach me is LinkedIn.

Message me on LinkedIn See all code on GitHub