OPEN TO SENIOR ROBOTICS / AUTOMATION ROLES — AUSTIN & SELECT REMOTE

Sam Snyder

Robotics Engineer · Automation · Precision Mechatronics

Featured projects Contact CV (PDF)
Austin, TX
sam@samhsnyder.com LinkedIn GitHub
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Sam Snyder
ROBOTICS • MECHATRONICS • MANUFACTURING
About

Dynamic automation and robotics engineering leader with over a decade of hands-on experience designing and deploying vision-guided robotics, precision mechatronics, control systems integration, and DFM/DFA-optimized manufacturing solutions.

Proven in scaling prototypes to high-rate production in agile, high-growth environments, including a successful tech startup exit after growing a distributed-compute platform to millions of users.

Expert in integrating ROS2, micro-ROS, ESP32, PLCs, and AI-driven systems for complex, high-precision applications across defense, advanced manufacturing, and industrial automation.

Based in Austin, TX. Strong foundation in Physics at Stony Brook University and Mechanical Engineering studies at NYU. Passionate about end-to-end hardware + software ownership in robotics and advanced manufacturing.

5+
years deep stack
2.5M
users scaled (Gamma)
60%
cost reduction (winding)
5–10 km
UAV standoff
Experience

Prototype to production at scale.

Nov 2025 – Present

Systems Engineer, Hardware/Automation — Ukrainian Unmanned Vehicle Battalion (Kharkiv / remote)

  • Managed cross-functional teams of 8–12 and trained UAV pilots on advanced remote/autonomous systems in high-threat forward environments.
  • Led electrical + mechanical design, rapid prototyping and R&D — reduced new drone feature dev time by ~40%.
  • Designed remote-activated drone launch boxes enabling 5–10 km standoff operation, minimizing operator exposure beyond the zero line of contact.
  • Developed kamikaze drone hibernate/sleep + multi-sensor (accel/PIR/seismic) triggering; achieved 47-day standby and 60–75% improved strike success in contested EW via low-power/low-detectability.
  • Built supporting mesh (LoRa + Meshtastic + ExpressLRS), FastAPI/WebSocket HMI, ROS2 digital twin, and two-person crypto auth systems. 7 launch boxes + 23 airframes fielded.
ROS2 • ESP32-S3 • LoRa/Mesh • FastAPI • Field deployment
May – Nov 2025

Head of Automation — Pascal Tags (Louisville, KY)

  • Commissioned full end-to-end automation for Nordson ProPlus4 robotic syringe printer in chipless RFID production using Rockwell Allen-Bradley Micro 820 PLC.
  • Designed and implemented custom multiplexed binary protocol over 8 digital I/O channels (3-bit tag position + 4-bit bit index) with deterministic FIFO sequencing, fiducial compensation, and integrated UV cure control. Scaled from 42 tags/hr semi-manual to automated traceable production.
  • Built hybrid FastAPI + WebSocket HMI (pycomm3 Ethernet/IP) for real-time monitoring, CSV job upload (up to 1,999 tags), and operator control. Time-critical logic stayed on PLC; server handled sequencing/UI.
  • Designed 3D-printed fixtures (UV cure mounts with heat fins, 8-up magnet tag holders, Nordson clamps), Arduino-controlled vacuum pick-and-place tag applier, and automated FR4 card dispenser (elevator + photogate + servo trap door).
  • Produced full production scaling roadmap + CapEx model targeting 5M–10M tags/year; supported DoD uniform tagging and Brown-Forman barrel applications.
Allen-Bradley Micro 820 • Nordson • FastAPI/WS • pycomm3 • SolidWorks • 3D printing • DFM
Apr 2024 – May 2025

Director of Production — Canyon Magnet Energy (Stony Brook, NY)

  • Oversaw production of high-temperature superconducting (REBCO) electromagnets for fusion and space propulsion applications.
  • Designed and built first-generation robotic winding table (pay-off spool + tension control, servo-driven mandrel with encoder, Beckhoff TwinCAT real-time controller + CAM tables). Cut production cost 60%, increased throughput 30%.
  • Enabled prototype rates of 10–20 coils/month with documented path to 50–100/month via fixtures and process. Led technical pitches securing fusion/aerospace partnerships.
Beckhoff TwinCAT • Servo motion • REBCO winding • Cryogenics • DFM • Supply chain
2019 – 2024

Engineering Director — AJC (New York, NY)

  • Directed precision manufacturing for a metal foundry serving Apple, Samsung and other high-end clients using 5-axis CNC, lost-wax casting, and 3D printing (SLA/FDM).
  • Achieved 150% YoY growth, doubled client base to 50+, reduced production timelines 62% via CNC optimization and process improvements. Managed 8-person shop floor.
5-axis CNC (HAAS/Fanuc) • Lost-wax • 3D printing • GD&T • Team leadership • DFM/DFA
2016 – 2019

Co-founder & COO — Gamma Innovations, Inc. (Los Angeles, CA)

  • Co-founded distributed supercomputer platform (consumer GPU/CPU marketplace). Raised $2.7M from top VCs and angels (Unity, Google Maps, Zynga, Greycroft, Razer).
  • Scaled to 550K+ downloads, reached profitability, drove successful exit (acquired by Animoca Brands, Jun 2019).
Fundraising • Distributed systems • Marketplace • M&A • Team scaling (2.5M users)
Featured Projects

Real hardware. Real software. Real constraints.

6-DOF Robotic Arm + Aero Hand

ACTIVE

Client-commissioned BCN3D Moveo (6-DOF) with fully-actuated Aero Hand gripper. End-to-end autonomous pick-and-place via computer vision on Raspberry Pi ROS2 stack.

ROS2 Jazzy MoveIt2 ESP32-S3 + micro-ROS OpenCV (eye-in-hand) URDF/Xacro
  • • Real-time joint state (target 10 ms cycle), MoveIt2 IK/trajectory planning
  • • micro-ROS agent on ESP32-S3: 5× stepper drivers + servo gripper, quadrature feedback, OTA
  • • Stereo vision plan + hand-eye calibration for visual servoing (5–10 mm target accuracy)
ROS2 • micro-ROS • firmware ↔ motion planning ↔ CV

Pascal Tags — Full Automation Stack

MANUFACTURING

Head of Automation for chipless RFID tag production. Custom 8-channel binary protocol over PLC I/O, FastAPI/WebSocket HMI, 3D-printed 8-up fixtures, 5 µm fiducial-compensated dispensing, UV cure integration. Full scope & architectures in repo.

Allen-Bradley Micro 820 Nordson ProPlus4 FastAPI + WebSocket pycomm3
  • • Custom 8 I/O binary protocol (3-bit position select + 4-bit bit index) with run pulse, fiducial correction, UV cure integration
  • • 3D printed production tooling: UV cure heads, 8-up magnet fixtures, Nordson clamps, vacuum pick-and-place applier, FR4 dispenser
  • • Full rate + CapEx model for 5M–10M tags/year scaling
PLC ↔ device protocol design • Hybrid real-time control + modern HMI pattern

Superconducting Magnet Winding Table

MANUFACTURING

Beckhoff TwinCAT real-time + servo + tension control for REBCO HTS tape. 60% cost reduction, 30% throughput increase. CAM tables for complex coil geometry. Prototype → production path documented.

Beckhoff TwinCAT Servo Motion Tension Control CAM Tables
  • • Real-time controller + CAM tables for complex coil geometry
  • • 60% cost reduction, 30% throughput increase vs manual winding
Real-time controls • DFM • HTS tape winding • Prototyping

Valstad QC Laser Profiling Gantry

CAD + GD&T

Complete mechanical design + BOM + rigorous tolerance stack analysis for a 20 m laser profiling quality control station targeting ±0.1 mm accuracy over full range.

SolidWorks GD&T / Tolerance stack Hiwin • Renishaw • Gocator
  • • Full cumulative error analysis from optics mount through long-range rails to sensor alignment
  • • Modular phased architecture (manual Phase 1 → servo motion Phase 2) with repeatable kinematic datums
  • • Production-ready BOM with QA checkpoints and sourcing for 20 m precision linear motion
Precision long-range metrology • Shipyard QC DFM

FANUC RMI Mock + Moveo Bridge

INTERVIEW ARTIFACT

Reverse-engineered full FANUC RMI server (from valstad-shipworks/fanuc_ucl serde models). Drives real physical BCN3D Moveo 6-DOF arm using the library's own unmodified example code.

Python stdlib JSON TCP (16001/16002) Protocol reverse-eng
  • • Complete handshake, strict FIFO blocking motion commands, JointMotion, Linear, status, I/O, UFrames
  • • Pluggable bridges (sim with 3D viz, direct rclpy ROS2, Pi TCP socket) matched to real arm firmware contract
  • • Exact handling of FANUC J2/J3 coupling as the real library expects
Protocol reverse-engineering • Exact RMI fidelity (FIFO, J2/J3 coupling) • Pluggable sim/ROS2/physical bridges

'OpenSesame' Auto Door Handle

WEEKEND

ESP32-S3 + BLE iPhone app + L298N DC gear motor + limit switches + 3D-printed drive. Full open-hold-close cycle on tap. Daily driver on apartment door. Shows firmware + mechanism + UX integration.

ESP32-S3 BLE 3D Printing
  • • Weekend project: I had misplaced my key fob too many times...
Real-time controls • Actuation • BLE firmware • End-to-end ownership

Deeper demos, videos, and private repo access available on request. Many pieces were built for clients or interview validation.

Skills

Firmware to factory floor.

Robotics & Motion Control

ROS2 JazzyMoveIt2micro-ROS URDF/XacroFANUC RMIOpenCV Visual ServoingKinematics + IK

Embedded & Firmware

ESP32-S3 (FreeRTOS)Arduino / C++PWM + Quadrature SPI / I2C / CAN / UARTOTA updatesDeterministic loops

Controls & Industrial

Allen-Bradley Micro 820Beckhoff TwinCAT Ladder + Structured TextEtherNet/IP (pycomm3) Real-time CAM tablesBinary/JSON protocol design

CAD & Mechanical Design

SolidWorksFusion 360Onshape Rhino 3D + KiCADGD&TDFM/DFA FEA (ANSYS)5-axis CNC toolpaths

Manufacturing & Production

High-rate production scalingVision-guided robotics cells CNC + robotic automationCapEx + rate modeling 80/20 + custom fixturesTolerance stack analysis

Software & Systems

Python (primary, 10k+ LOC)C++ (real-time/embedded) FastAPI + WebSocketGit + GitHub Actions ROS2 nodes + launch filesTailwind/JS UIs
Education
Physics — Stony Brook University
Mechanical Engineering — NYU Tandon
Product Design — Parsons School of Design
Contact

Let's build precise things.

sam@samhsnyder.com
linkedin.com/in/samhsnyder
github.com/ss1-ops
Download CV
Source: github.com/ss1-ops/ss1-ops.github.io