// realdarkfactory.com  ·  node-01 // therealdarkfactory.com  ·  node-02
online

// AI systems architecture & autonomous operations

The RealDark Factory

I build AI systems that run on hardware, not just in the cloud.

Thirty years of embedded engineering — from the first instruction after reset, through the drivers and the operating system, up to the application architecture on top — pointed at machine learning that has to work on a board with a power budget, in a room with people in it, without an engineer standing over it.

Accepting select engagements

// annunciator panel · lamp test

every lamp lit deliberately, to prove none has failed

Edge inference Unattended run Quality gates Diagnostics Provenance Degrade, not halt

// the premise

A dark factory runs unattended. This one runs in a bright room.

A classic dark factory needs no accommodation for humans, because there are none: lights off, noise irrelevant. The systems I build are fully automated while surrounded by people, during something that matters to them. That inverts the defaults. Silence becomes a requirement. Motion becomes a distraction. And failure has to degrade, never halt — because the thing in front of the audience does not stop.

// capabilities

Three things, done properly rather than ten done adequately.

Edge & on-device inference

Models that run on the metal, inside a real power and thermal envelope — where latency is measured, not assumed, and the network is optional.

  • NPU and accelerator bring-up
  • Quantisation and throughput measurement
  • ARM, Intel, RISC-V · Linux, RTOS, bare metal
  • Power, thermal and cost budgets

Systems that run unattended

Production pipelines with no human in the loop, built to refuse rather than guess. A stage that cannot verify its own output stops and says so.

  • Quality gates proven by making them fail
  • Provenance and audit trails
  • Structured, machine-readable diagnostics
  • Multi-agent orchestration and review

Architecture & hard review

Hardware and software designed together, from schematic to boot to application — and reviewed adversarially before anyone believes it works.

  • Hardware / software co-design
  • Multilayer PCB layout, power electronics, EMC
  • Design for diagnosis and field service
  • Standards compliance (IPC, IEC, AES)
  • Technical due diligence

// measured, not claimed

A wrong number that looks right is worse than a crash.

The Real Dark Factory Specifications
5.3×
Inference throughput recovered on one accelerator board, same model, same silicon
4×
Production test time cut on a four-up bed-of-nails fixture, avoiding a second six-figure test line
20+
Languages in a production publishing pipeline that runs without an operator
30+
Years of embedded and systems engineering, from boot code up

A Hailo-8 accelerator benchmarked at 58.7 frames per second. Nothing had failed. The board was healthy, the model was correct, and the run completed cleanly.

The compiled binary had been built for the Hailo-8L — the 13 TOPS part — and was running on the 26 TOPS Hailo-8. The vendor's own tool spotted it, printed a one-line warning, and ran it anyway. The right build measured 309.4 FPS on the same board with the same model: 5.3×, from a filename suffix.

That is the failure worth designing against. Not a crash — a plausible number. It looks like it works, it produces a figure you would happily put in a report, and nothing downstream can tell that it is wrong by a factor of five.

58.7 309.4 FRAMES / SEC
same board · same model

// record

The same job, in six industries that have almost nothing to do with each other.

An eclectic engineering background, and the list is the point. Precision bench instruments. Medical devices under FDA. Carrier networking. Consumer audio at very high volume. Defence research. Now AI on hardware. Different products, different regulators, different decades — and underneath all of them one problem: knowing whether the thing actually works.

MIT Lincoln Laboratory
Low-power wireless networking research — an IPv6 stack over IEEE 802.15.4 for constrained devices, before that combination was something you could download.
Cisco Systems
Five years on a $1B product line — a carrier gateway carrying voice, fax and data, with up to several hundred digital modems in one chassis. Wrote the boot code and drivers, led the diagnostics team that built the diagnostic architecture for its multiprocessor boards, and ended up running the project: owning the phase-two plan and driving the engineering specification across vendors, marketing and several engineering groups. Senior, then principal, then project engineer, on the same product.
Siemens Medical
Ran the engineering department — twenty-five engineers and technicians. Rebuilt a manufacturing floor around complete data logging and unit-level traceability, and those records were among the things the FDA noted favourably when the site was recertified.
Bose
Cut a four-up production test from twenty minutes to five, by running subsystem tests concurrently wherever they could not contend for the same hardware: radio MAC programming and firmware update on one path, memory, keypad and antenna checks on others — with results written where a firmware upgrade could not erase them. One line did the work of two. Technical lead for the engineers and technicians who took the product into Bose's Mexican board and final-assembly plants. Earlier, on their first streaming radio, argued for instrumenting the product before launch: correlating field failures against environment, and learning what people actually listened to and when. As an outside consultant, with no authority to make it happen.
GenRad · BTU International
Where the habit started. Diagnostics and test in C for precision bench instruments, then the functional-test boards, embedded diagnostics and programmable electronic loads built to exercise product on the line.
OpenScorpion
Open source. Six regional models detecting venomous scorpions, spiders, snakes and centipedes — split along Brazil's official IBGE biome boundaries, because the fauna is split that way and one national model would be worse at every point in it. mAP50 0.92 to 0.98 across nine to sixteen classes each, trained on roughly 42,000 field images spanning 126 species. One training pipeline feeds two hardware tiers: a Pi Zero 2 W running a binary dangerous / not-dangerous decision at the price a rural household can actually afford, and a Pi 5 doing species-level identification for research deployments. On hold while revenue work takes priority — a scheduling decision, not a technical one.
Current work
Retrained deliberately from 2023 rather than assuming thirty years of embedded work would transfer on its own: embedded machine learning and TinyML, CUDA, PyTorch, AWS IoT. Since then — a multi-camera edge product in active development, operator-driven, controlled from a web interface, up to three cameras, all inference on the box; an automated multi-language publishing pipeline in production; and an internal multi-agent review system used on decisions that are expensive to reverse.

// how I work

Five rules, each of them learned the expensive way.

Design for diagnosis

Spend the parts. Internal loopback, bounded ring buffers, an identity record on every board. A box that cannot tell you why it failed costs more in field service than the components you saved by leaving them off.

Degrade, never halt

A factory can stop the line and wait for a technician. A system performing in front of people cannot. Whatever fails, something sensible keeps going out.

A gate that has never failed is a claim

Not evidence. Corrupt a known-good artefact in exactly the way the check exists to catch, and watch it bite. Until then you have a test that only knows how to pass.

Data is the instrument

A model does not improve because someone thought hard about it. It improves because the cases it got wrong were collected, looked at, and fed back. Without that loop quality stops moving at whatever level it happens to be sitting — and the worse part is that you cannot tell it has stopped.

Verify before asserting

Especially before saying something does not exist, is not wired up, or cannot be done. Read the code. Take the measurement. Inference is how confident wrong answers get made.

// contact

Tell me what is not working.

Or

Remote consulting in AI systems, edge AI and embedded machine learning: architecture, review, and finding out what is actually happening. Short engagements welcome — a week of measurement is often worth more than a month of opinion.

Happy in front of your customers as well as your engineers — a lot of this work has been explaining a technical position to the people who have to buy it.

Useful things to send with a first message: what the system has to do, what it is doing instead, and how you know.

United States · remote
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