
Afshar Mahmoudi
Verified Expert in Engineering
Systems Engineer and Developer
Rome, Metropolitan City of Rome, Italy
Toptal member since April 27, 2026
Afshar is a mechanical engineer specializing in automation and control systems, with experience in PLC programming (Beckhoff TwinCAT), system architecture, and real-time data acquisition. He is skilled in building scalable industrial software, integrating sensors, and developing diagnostics. Afshar is also experienced in lab instrumentation, biomaterials, Atomic Force Microscopy (AFM) testing, and data analysis, bridging industrial systems with research environments.
Portfolio
Experience
- HVAC - 5 years
- CODESYS - 3 years
- Beckhoff PLC - 3 years
- Laboratory Instrumentation - 3 years
- SQL - 3 years
- TwinCAT PLC - 3 years
- Biomaterial - 2 years
- Atomic Force Microscopy (AFM) - 1 year
Preferred Environment
TwinCAT PLC, CODESYS, MATLAB, SQL, Visual Basic for Applications (VBA), OPC UA, Modbus Protocol, Microsoft Excel, Visual Studio, SCADA
The most amazing...
...thing I've designed is a control classification engine, mapping 8,000 room layouts into 1,000 reusable PLC software types—cutting engineering & deployment time.
Work Experience
Automation & Control Systems Engineer
Evolvea
- Developed modular PLC control systems using Beckhoff TwinCAT 3 and Codesys across large-scale infrastructure projects, enabling scalable and reusable automation architectures.
- Designed a classification engine, mapping around 8,000 room configurations into 1,000 reusable control software types, significantly reducing engineering and documentation effort.
- Automated functional design specification (FDS) generation using SQL and VBA, reducing documentation time from days to minutes while improving consistency and traceability.
- Built real-time data acquisition pipelines, integrating Modbus devices with OPC UA communication, enabling reliable telemetry and system-level monitoring.
- Implemented diagnostic and validation logic to detect configuration mismatches and control inconsistencies prior to deployment, improving system reliability.
- Integrated elevator telemetry (status, motion, floor detection) into supervisory systems, enhancing monitoring and operational visibility.
- Collaborated with cross-functional teams (BIM, commissioning, QA) to align control logic with system design and installation constraints.
- Developed internal automation tools and workflows beyond the assigned scope, improving delivery speed, engineering efficiency, and system robustness.
Research Engineer – Biomaterials & AFM Characterization
Technical University of Vienna
- Conducted AFM-based nanoindentation experiments on collagen fibrils in liquid environments (PBS), analyzing mechanical properties under controlled biochemical conditions.
- Designed and refined experimental protocols to ensure reproducibility, including controlled measurement positioning and standardized sampling procedures.
- Investigated effects of glycation, enzymatic digestion, and thermal variation on ECM mechanics through long-term, multi-stage experiments.
- Developed MATLAB-based analysis workflows for force–distance curve processing and mechanical property extraction.
- Monitored and recorded environmental parameters (pH, temperature, incubation timing) to maintain controlled and traceable experimental conditions.
- Identified and handled experimental anomalies through data validation strategies, distinguishing measurement artifacts from true material behavior.
- Documented and iteratively improved laboratory protocols based on experimental outcomes, enhancing repeatability and reliability of results.
- Collaborated with multidisciplinary research teams on experimental design, data interpretation, and mechanobiology studies.
HVAC Systems Engineer & Project Coordinator
LG HVAC
- Designed and delivered HVAC systems for residential and commercial projects, including villas and multi-unit buildings, covering system sizing, layout, and installation.
- Performed thermal load calculations and system selection for duct split and HVAC solutions, optimizing performance based on climate and building requirements.
- Managed installation teams on-site, coordinating workflows, supervising quality, and ensuring timely project delivery.
- Established and operated an HVAC sales and service branch, expanding from small-scale systems to larger residential and commercial projects.
- Introduced pre-insulated duct systems to local projects, improving installation efficiency and thermal performance.
- Oversaw piping, ducting, and electrical integration, including coordination of system components and basic control wiring.
- Diagnosed and resolved system performance issues in installed HVAC units, improving reliability and customer satisfaction.
- Prepared project estimates and technical proposals, aligning system design with budget and client requirements.
Experience
Scalable PLC Architecture for Large-scale Building Automation
I engineered a classification system that mapped 8,000 room configurations into 1,000 reusable control software typologies, significantly reducing engineering effort and enabling rapid deployment. I also built automated documentation pipelines using SQL and VBA to generate FDS, improving consistency and traceability.
Additionally, I integrated real-time data acquisition systems using Modbus and OPC UA, enabling reliable telemetry, diagnostics, and system monitoring. I developed validation and diagnostic tools to detect configuration inconsistencies prior to deployment, enhancing system reliability and reducing commissioning issues.
AFM-based Mechanical Characterization of Collagen for Biomaterials Research
Additionally, I designed reproducible experimental protocols by implementing controlled measurement positioning and standardized sampling strategies, ensuring consistent testing across long-term experiments. I investigated the effects of glycation, enzymatic degradation, and thermal variation on the mechanics of the extracellular matrix (ECM).
I monitored and controlled environmental parameters, including pH, temperature, and incubation timing, to maintain traceable experimental conditions. I developed data validation strategies to identify measurement artifacts and ensure data integrity. I also iteratively refined laboratory protocols to improve repeatability, aligning with structured and regulated laboratory practices relevant to biomedical and pharmaceutical environments.
Design & Deployment of HVAC Systems for Residential & Commercial Projects
I managed on-site installation activities, coordinating teams and supervising ducting, piping, and system integration. I introduced pre-insulated duct systems to improve installation efficiency and thermal performance.
I also oversaw system commissioning and troubleshooting, identifying performance issues and implementing corrective actions to enhance system reliability. I prepared technical proposals and cost estimates, aligning engineering solutions with client requirements and project constraints.
Education
Master's Degree in Mechanical Engineering
Sapienza University of Rome - Rome, Italy
Certifications
Machine Learning
Stanford Online | via Coursera
PLC Object Oriented Programming
Udemy
SQL for Data Science
UC Davis | via Coursera
Skills
Tools
TwinCAT PLC, Microsoft Excel, Beckhoff PLC, MATLAB, Visual Studio, AutoCAD, Supervisor
Languages
SQL, Visual Basic for Applications (VBA)
Paradigms
Automation, Database Design, Mechanical Design, Thermal Management, Object-oriented Programming (OOP)
Frameworks
Nano
Other
CODESYS, PLC, Atomic Force Microscopy (AFM), HVAC, Troubleshooting, OPC UA, Modbus Protocol, Control Systems Design, Nanoindentation, Force Spectroscopy, Biomaterial, Mechanobiology, Experimental Research, Data Analysis, Documentation, HVAC Design, Automations, Nano-Indedtation, SCADA, Experimental Design, Sample preparation, Laboratory Instrumentation, 3D Printing, Fluid Mechanics, Metallurgy, Renewable Energy, Control Systems, System sizing, Project Planning, Cost Estimation, Human-machine Interface (HMI), Machanobiology, Scientific Documentation, Ventilation Design, System Sizing, Installation Supervision, Machine Learning, Unsupervised Learning, Recommendation Systems, Reinforcement Learning, Regression, Classification, Decision Trees, Deep Learning
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