Hardware Design
From first schematic to production-ready PCB, with an eye on signal integrity, EMC, and manufacturability.
Hi, I'm
Fawzi Fansa
Inventor. Builder. Entrepreneur. Embedded systems. Traveller. Hiker. Curious mind.
I turn complex problems into working electronics.
Founder · Fusion Sensorik & Messtechnik GmbH
About
A decade at the intersection of hardware and software.
I've spent over ten years designing electronics that don't get seen — the kind that go inside industrial machines, sensors, and systems built to run for years without failure.
I started in Cairo, studied embedded systems at TU Chemnitz, and have since worked across Germany alongside international research stints at INSA Lyon, Rome, and NC State. In 2025, I founded Fusion Sensorik & Messtechnik GmbH.
I work best at the full stack of a hardware product: from schematic to PCB layout, from bare-metal firmware to the tooling that runs on a production line. I take ownership of problems — not just slices of them.
Expertise
What I build with.
Ten years of working across the full hardware stack — from blank schematic to certified product.
Firmware Development
Bare-metal C for resource-constrained systems. Clean, efficient, and built to run for years.
Software Tools
C# desktop tooling for production lines — calibration, flashing, logging, and test automation.
Industrial Protocols
Deep experience integrating devices into real industrial networks across a wide range of standards.
Microcontrollers
Hands-on with a broad range of MCU families across different architectures and peripheral sets.
Prototype to Production
I take products through the full journey — from early prototype to certified, manufacturable series.
Services
How I can help.
Available for project-based engagements, long-term contracts, and consulting retainers.
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Freelance Consulting
Architecture reviews, technical audits, and feasibility studies. I help teams make better decisions before they build — and fix expensive ones after.
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Hardware Design & Redesign
Full PCB design from schematic to layout, or redesign of existing hardware for improved reliability, cost reduction, or modernisation.
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Firmware Development
Bare-metal or RTOS-based firmware in C/C++. Peripheral drivers, communication stacks, bootloaders, and production-ready device software.
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Prototype to Production
I take early-stage prototypes through DFM, EMC/IP certification, and the full transition to manufacturable, certified series hardware.
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Component Replacement & Legacy Redesign
Replace obsolete or end-of-life components, redesign legacy boards, or port existing firmware to new silicon — without starting from scratch.
Portfolio
Selected work.
A cross-section of projects from the past decade — hardware, firmware, and the tooling that connects them.
Industrial Heating Controller Firmware
Developed firmware for four series of industrial heating controllers. Covers temperature regulation algorithms, sensor interfacing, and safety logic for continuous industrial use.
Analog Retrofit Module
Designed a drop-in analog interface module supporting 4–20 mA and 0–10 V signal standards, enabling legacy system upgrades without controller replacement.
CAN Bus Module
End-to-end design of a CAN connectivity module deployed across five controller series. Includes physical layer, protocol stack implementation, and diagnostic tooling.
Modbus Module
Modbus RTU/TCP interface module for industrial devices. Full register map implementation, exception handling, and production-tested reliability.
Profibus Connectivity Module
Profibus DP slave implementation for field device integration. Designed from hardware schematic through to certified firmware with full GSD file.
Vacuum Sensor — Prototype to Series
Took a vacuum sensor from initial prototype through full EMC and IP certification into series production. Covers PCB design, firmware, and DFM optimisation.
C# Production Tooling Suite
Desktop application suite for production line operations — device flashing, calibration, functional testing, and traceability logging across multiple product lines.
MEMS Sensor Interface
Custom interface board and firmware for a MEMS inertial sensor. Includes signal conditioning, SPI driver development, and data validation routines.
WiFi PoC Module
Proof-of-concept WiFi connectivity module for an industrial device. Covers embedded TCP/IP stack integration, OTA update mechanism, and power management.
Experience
- 2025 — present Founder Fusion Sensorik & Messtechnik GmbH Berlin, Germany
- 2021 — 2025 R&D Firmware & Hardware Engineer Winkler AG Germany
- 2019 — 2021 Electronics R&D Engineer, Team Lead VACOM Jena, Germany
- 2017 — 2018 Research Assistant (HiWi) TU Chemnitz Chemnitz, Germany
- 2014 — 2015 Co-Founder I-Solar Smart Systems Cairo, Egypt
Education
- 2015 — 2018 M.Sc. Embedded Systems TU Chemnitz Thesis grade: 1.0
- 2007 — 2013 B.Sc. Electrical & Communications Engineering British University in Egypt Cairo, Egypt
Blog
Writing.
Occasional notes on embedded systems, hardware design, and the business of building things.
Image Layout Test
Testing side-by-side images with captions and a photo carousel.