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Aidan Korpar

Automation Engineer

Transforming complex engineering challenges into innovative automation solutions

About Me

I am a Control Systems Engineer with a Bachelor's degree in Mechatronic Engineering. My professional expertise lies in PLC programming, robotics, CAD design, and automation solutions.

I thrive on solving complex engineering challenges and leading teams to successful outcomes. My hands on experience includes programming automated manufacturing lines, troubleshooting existing systems, and developing innovative solutions in warehousing and industrial automation.

Beyond my technical capabilities, I have taken on leadership roles as a youth development instructor with the Army Cadets and as the founder, events director, and president of a university engineering society. These experiences have sharpened my ability to guide teams, foster collaboration, and communicate effectively.

PLC Programming Expert
Industrial Robotics
Team Leadership
Aidan Korpar
0 Years Experience

Professional Experience

Patrick Terminals: Process and Automation Engineer (0 years and 0 months)

As a Process and Automation Engineer at Patrick Terminals, I work across a broad range of functions, collaborating with individuals and teams at every level. My role spans from hands on technical support and troubleshooting of our automated systems, including Automated Rail Mounted Gantries (ARMGs), AutoStrads, and auto cranes, to contributing to proposals and planning for future automation projects.

A significant part of my work involves data analysis, using it to identify deficiencies in our operations and drive measurable improvements in efficiency across the yard. I take findings from that analysis and translate them into practical steps that teams can act on.

I am also involved in the risk and safety analysis of upcoming projects, helping to ensure that new developments are assessed thoroughly before implementation. On larger, more complex projects I have contributed to the coordination side as well, including developing file management frameworks for multi phase projects where multiple vendors are working toward a shared outcome.

The role is fast moving and varied, and I thrive in that environment. Each project and challenge brings something different, and I enjoy adapting quickly, finding solutions, and contributing wherever I can across the operation.

Port Container Flow Visualisation

Interactive Streamlit Sankey dashboard for tracing container movements through the terminal with live filtering and flow analytics.

Python Streamlit Sankey / Plotly Pandas Terminal Logistics
View Project

Port Container Flow Visualisation is an interactive web application built to analyse how shipping containers move through a port terminal from vessel discharge, through the yard, and out via truck or rail, as well as the reverse flow for outbound loads.

The live demo is published on Streamlit Community Cloud and uses entirely synthetic sample data, so it can be embedded publicly on a personal website without exposing any operational databases or company credentials.

The dashboard presents the container journey as a Sankey flow diagram, making it easy to see which berths, yard blocks, vessels, and transport modes drive the most volume, where re-handles occur, and where movement sequences contain data gaps.

Key Features

  • Interactive Sankey diagram with click to highlight path tracing
  • Sidebar filters for date range, vessel, flow direction, cargo category, berth grouping, and minimum volume threshold
  • Analytics tab with summary statistics, top routes, vessel breakdowns, and origin/destination rankings
  • Data gap diagnostics that surface orphaned or broken movement sequences
  • Step volume cards that show how container counts change across the journey

Technology Stack

  • Python and Streamlit for the application layer
  • Plotly for the Sankey visualisation
  • Pandas for filtering, grouping, and aggregation
  • Bespoke JavaScript for node and flow highlighting inside the chart

Open live demo

Crossmuller: Control Systems Engineer (0 years and 0 months)

From June 2022 to March 2026, I worked at Crossmuller as a Control Systems Engineer, gaining hands on experience across multiple industrial automation projects. My work involved PLC programming using Siemens TIA Portal, Factory Acceptance Testing (FAT), and the integration and programming of Fanuc industrial robots. I contributed to the design, programming, troubleshooting, and commissioning of automated warehousing systems and manufacturing lines, with a focus on improving reliability and efficiency.

Through this role, I have developed both technical and professional competencies, particularly in managing multiple concurrent projects and maintaining structured documentation. Tracking tasks and documenting design decisions have allowed seamless transitions between projects and improved collaboration during handovers. Guidance from experienced colleagues has also helped refine my documentation and workflow practices, improving both technical clarity and project efficiency.

Emulate3D Virtual Commissioning

Full laminating line digital twin for FAT-ready PLC validation across 12 networked PLCs before hardware arrives on site.

Emulate3D Siemens TIA Portal 12x Networked PLCs FAT Validation Digital Twin
View Project

This project delivered a full Emulate3D simulation of the Laminating Line at the Mount Gambier site, spanning approximately 12 PLCs communicating with each other.

The virtual twin was configured to spawn and despawn product with real time timing and physics while running live PLC code, allowing complete Factory Acceptance Testing (FAT) before hardware arrived on site.

Emulate3D Video Carousel (Links Coming Soon)

Industrial Robot Programming and Integration

Fanuc robot programming for glut handling on a strapping line with vision-based height scanning and Profinet PLC integration.

Fanuc Robotics Profinet Roboguide TP / LS / Karel FAT Commissioning
View Project

My most recent work involved programming a Fanuc robot for use as a glut handling robot on a strapping line at a new factory. The robot was designed to pick gluts from a stillage by scanning for the next heights glut in the stillage and then adjusting its pick position accordingly before picking the glut and then moving to the strapper channel to place the glut.

I was responsible for programming the robot's pick, place, movement and scanning sequences to detect glut locations within the stillage, as well as configuring communication between the robot and the Siemens PLC via Profinet. The robot was programmed using ls and tp code with some karel functions for more complicated sections. Fanuc Roboguide was used to simulate and test the robot before Factory Acceptance Testing (FAT) was started. This was performed within the factory where I was able to verify motion sequences, and troubleshoot integration issues between the robot, PLC, and line control systems along with testing the new SCADA interface.

This project strengthened my understanding of industrial robotics, detection logic, and robot to PLC communication protocols. It also reinforced the importance of structured testing, clear fault diagnosis, and collaboration across engineering disciplines during commissioning.

Glut Robot FAT

Pack Turning Cell

Automated manufacturing cell for flipping laminated boards with end-to-end control system programming, safety integration, and commissioning.

Siemens PLC Drives & VFDs Machine Safety Multi-PLC Interlocks Site Handover
View Project

One of the projects I completed from initial programming through to commissioning and customer handover was the Pack Turning Cell. This automation cell was added onto an existing manufacturing line to automatically flip one sided laminated boards to prevent bowing during storage and transport. This was the first project where I was solely responsible for the control system.

During this project, I gained extensive experience with drives, motors, and sensors, as well as practical understanding of machine safety standards including the implementation of light curtains and emergency stop systems. I also worked on multi-PLC communication to safely coordinate between production lines.

Commissioning presented several challenges that required patience and problem-solving. From debugging minor logic errors to recovering sensor calibration losses caused by PLC memory faults, each issue provided valuable lessons in troubleshooting under pressure. Despite an incident that resulted in damage to a safety fence and light curtain, corrective actions and collaboration with on-site teams ensured the line was restored without impacting production. The experience emphasised the value of perseverance, strong documentation, and clear communication during live commissioning.

Pack Turner In Operation

Leadership

Youth Development Instructor, Army Cadets

As a 2nd Lieutenant and Company Directing Staff, I lead and mentor over 100 cadets and 3 staff members, ensuring their safety and fostering a supportive environment for their development. My role involves teaching leadership, teamwork, and technical skills, while guiding cadets through challenging environments to build confidence and practical abilities. I design engaging lessons, supervise activities and camps, and uphold high standards of discipline and professionalism, preparing cadets for future success.

Army Cadets activity

Founder, Events Director, and President of UTSMechSoc

During my time at university, I founded UTS MechSoc after identifying a gap in student engagement within mechanical and mechatronic engineering. The society attracted over 400 members in its first year. I led the creation of major initiatives such as an industry networking night with over 300 attendees, strengthening relationships between students and industry professionals.

As the President, I led a 20-member executive team focused on sustainable growth and deeper engagement. Under my leadership, membership grew by 45% from 418 to 608, with a healthy 22% retention rate. We ran 62 events with a combined reach of over 500 unique registrants and an average of 51 attendees per event, maintaining a strong 97% UTS student participation rate.

In 2025, MechSoc was awarded Rookie of the Year, recognising it as the most successful club within its first two years at UTS. This achievement validated the foundation we built and the culture of excellence we fostered, demonstrating the impact of strategic leadership and member focused initiatives.

I emphasised collaboration, strategic planning, and member development, ensuring every executive had defined responsibilities aligned with their strengths. These efforts built a culture of accountability and innovation, reflected in consistently high event attendance, balanced engagement across activities, and long-term member loyalty.

This role refined my leadership, stakeholder engagement, and data driven decision making skills, which have proven essential in guiding teams toward measurable impact in my professional career.

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Personal Projects and Academic Experience

Chase the Chicken

Real-world urban hide-and-seek web application fusing high-stakes tag mechanics with battle-royale shrinking zones and nightlife precinct discovery

React 18 Vite Leaflet & OSM Supabase Realtime PostgreSQL & RLS Cloudflare Pages

App Link: chasethechicken.pages.dev

About the Project: What It Is & How It Works
Chase the Chicken is a real-world urban hide-and-seek web application that fuses high-stakes tag mechanics with battle-royale shrinking zones and nightlife precinct discovery. Players gather in an urban precinct, scan a room QR code to enter a synchronized multiplayer lobby, and divide into competing squads: the elusive Chickens and the pursuing Hunters.

Once the match begins, Chickens must stay within dynamically shrinking precinct boundaries, navigate between local venues, and complete stealth photo check-ins to stay ahead of the hunters. Hunters track them across an interactive map using periodic location intel, zone shrink timers, and pub radar. The match concludes when hunters physically verify a chicken tag or the chickens survive the final zone collapse, with all players receiving full match recaps and photo vaults.

Technology Stack & Architecture
Built as a progressive web application with React 18 and Vite, the interface utilizes custom Vanilla CSS design tokens for ultra-responsive styling, fluid micro-animations, and full light/dark mode support. Interactive geospatial mapping is powered by Leaflet and OpenStreetMap (Nominatim), featuring custom non-concentric boundary slicing algorithms for dynamic zone shrinkage.

Real-time device synchronization is driven by Supabase Realtime broadcast channels and PostgreSQL with hardened Row-Level Security (RLS) policies. Deployed on Cloudflare Pages with automated CI/CD and strict Content Security Policies, the architecture adheres to a privacy-by-design framework: player locations exist purely in-transit without persistent tracking breadcrumbs, uploaded check-in proofs auto-purge after 24 hours, and venue foot-traffic analytics remain strictly anonymized.

Foz Prints

Headless eCommerce platform and engineered 3D printed Subaru interior upgrades

Next.js Shopify Cloudflare 3D Printing

Live Website: fozprints.com.au

The Background
I started Foz Prints to solve a problem I had with my own Subaru Forester SG. The factory interior plastics become brittle over time. Original replacements are either discontinued or ridiculously expensive, and most aftermarket options look terrible. I decided to design, model, and manufacture my own 3d printed replacement parts in Sydney, printing them in heat resistant ASA plastic so they can actually survive an Australian summer.

The Tech Stack
I wanted full control over the design and speed of the website, so I built a headless setup instead of using a standard template.

  • Frontend: A custom Next.js site hosted on Netlify.
  • Backend: Shopify to handle the secure checkout, inventory management, and payments.
  • DNS: Cloudflare to route traffic safely between the two systems.

The Build Process and Challenges
Handling both the physical product engineering and the web development at the same time threw up some interesting roadblocks.

  • The Prototype Graveyard: Getting a 3D printed part to perfectly match a twenty year old dashboard is incredibly difficult. It took dozens of CAD iterations to get the curves, snap fits, and surface textures exactly right before the parts looked like they actually belonged in the car.
  • Headless Routing: Connecting a Next.js frontend to a Shopify checkout was a difficult task. I had to correctly map the root domain to Netlify while isolating the secure checkout on a Shopify subdomain without taking the whole site offline.
  • Working Around Locked Code: To keep running costs low, I used the basic Shopify Starter plan. This meant the backend code was completely locked down. When the headless setup caused the checkout logo to trap users on a dead end page, I could not use custom JavaScript or third party apps to fix it. I had to build native navigation workarounds to get customers back to the main site.
  • Australia Post API Limits: Getting live shipping rates to work at checkout was another massive headache. The Australia Post API is incredibly strict. If a single product weight, box dimension, or suburb spelling was slightly off, the whole checkout would crash. Figuring out exactly how to format the data to keep the API happy took a lot of trial and error.
  • Leveraging AI as a Technical Partner: Building a custom web platform alone is tough, so I heavily utilised AI tools throughout the project. I used AI to help write custom code, debug Next.js routing bugs, and translate confusing Shopify documentation. Having an AI to bounce ideas off drastically sped up the troubleshooting process, especially when fixing weird DNS and API connection issues.
Personal server infrastructure dashboard

Personal Server & Custom Dashboards

Self hosted ecosystem powered by PostgreSQL, custom tax & finance engines, telemetry logging, and automation

PostgreSQL Docker & CasaOS FastAPI & Flask Tailscale VPN Home Assistant PWA & Telemetry

Infrastructure & Host Overview
Built on an HP EliteDesk 800 G5 featuring an Intel i7 processor, this self hosted server operates as a centralised, high availability compute and storage hub for custom web applications, automation pipelines, and containerised services. The system is managed via CasaOS and Docker Compose, providing a resilient, isolated environment for hosting internal services without cloud lock in or recurring SaaS subscriptions.

Centralised PostgreSQL Database Layer (tracker_db)
At the core of the server's data architecture is a containerised PostgreSQL instance serving as the central relational backbone across multiple custom microservices. Rather than scattering data across disparate SQLite files or third party cloud SaaS platforms, the system enforces structured schema isolation within a unified database:

  • tax schema: Backs the custom Tax Dashboard, storing categorised deduction records, multi year asset depreciation schedules, vehicle trip logs, and income statements.
  • lifestats schema: Ingests high frequency lifestyle telemetry, GPS coordinates, event timestamps, and photo metadata with multi user isolation.
  • finance schema: Maintains transaction ledgers, portfolio snapshots, asset balances, and historical pricing feeds.
  • Reliability & Backups: Implements automated database dumps and snapshot routines, ensuring high throughput, ACID compliance, and full data sovereignty under local control.

Australian Tax & Deduction Automation Dashboard (FastAPI & PostgreSQL)
A full stack compliance and analytics platform tailored to Australian Taxation Office (ATO) regulations for both PAYG employment and sole trader activities:

  • Custom Tax Engine: Automatically calculates deductions, marginal tax bracket liabilities, and Medicare levy thresholds across financial years.
  • Asset Depreciation Calculator: Computes multi year asset write offs using both Prime Cost (straight line) and Diminishing Value methods with customisable effective life spans and claimable percentages.
  • Vehicle & Travel Logbook: Tracks business kilometres and travel deductions compliant with ATO logbook methods.
  • Excel & Receipt Pipeline: Ingests historical deduction spreadsheets (Tax Deduction.xlsx) via an automated import pipeline and supports receipt file attachments stored in containerised volumes.

Life Stats Tracker & Telemetry (PWA & Analytics Viewer)
A real time personal telemetry logging system designed for fast, seamless habit and lifestyle tracking on the go:

  • Offline First Mobile PWA: Built with responsive HTML5, modern CSS, and a Service Worker (sw.js) allowing instantaneous single tap logging from mobile devices even without active internet connectivity.
  • GPS Geolocation & Media Logging: Records precise geolocation coordinates for activity heatmaps and supports photo uploads (such as culinary steak logs, daily routines, and entertainment tracking).
  • Resilient Backend Server: Powered by a lightweight Python server (stats_server.py) with dynamic database driver management (supporting both psycopg2 and pg8000) and automated local CSV fallback.
  • Interactive Visualisation Engine: Features a dedicated analytics dashboard (stats_viewer.html) displaying geographic heatmap distributions, chronological activity timelines, category breakdowns, and streak statistics.

Investment & Finance Analytics Dashboard (Flask & Background Workers)
A custom web application built with Python Flask and containerised in Docker on port 8095 for end to end investment monitoring:

  • Multi Asset Portfolio Tracking: Aggregates equities, ETFs, crypto holdings, and cash reserves into unified net worth calculations and allocation breakdowns.
  • Asynchronous Market Data Pipeline: Uses threaded background workers (background_worker.py) and an intelligent caching layer (cache_storage.py) to pull live market valuations and currency conversions without degrading UI responsiveness.
  • Historical Analytics: Generates interactive profit/loss reports, yield projections, and performance charts against market benchmarks.

Zero Trust Secure Remote Access (Tailscale)
All self hosted dashboards and services are securely accessible anywhere in the world via a Tailscale Zero Trust VPN mesh. By utilising WireGuard-based point to point encryption, all server ports remain completely closed to the public internet, eliminating attack vectors while providing low latency remote connectivity across mobile phones, laptops, and workstations.

Smart Home Orchestration, Document Authoring & Media Ecosystem
Beyond custom telemetry and financial tools, the server hosts:

  • Smart Home Hub: Home Assistant and a dedicated Matter Server coordinating IoT devices locally with zero cloud reliance.
  • Overleaf / ShareLaTeX: A private, containerised collaborative LaTeX editor for authoring academic and technical engineering documentation locally.
  • Media Suite: Jellyfin and Jellyseerr for private high definition streaming, hardware transcoding, and automated metadata curation.
Professional ePortfolio Website

Professional ePortfolio Website

AI assisted web development using LLMs and GitHub Copilot

HTML/CSS/JS AI Collaboration Responsive Design

This professional ePortfolio website represents a modern approach to web development, combining traditional programming skills with cutting edge AI collaboration tools. The project showcases my ability to effectively leverage Large Language Models (LLMs) and AI assisted development workflows to create a polished, responsive web presence.

Throughout the development process, I utilised multiple AI platforms including ChatGPT, Google Gemini, and Claude to explore different design approaches, troubleshoot issues, and refine the user experience. Each LLM brought unique strengths to the project. From generating initial HTML/CSS structures to optimising responsive layouts and suggesting best practices for web accessibility.

A key aspect of this project was my experience with GitHub Copilot's agent based workflow. Rather than simply accepting code suggestions, I approached the development process as a project manager, assigning specific tasks and roles to AI agents, reviewing their proposed changes, and iteratively refining the output. This workflow involved:

  • Task Delegation: Breaking down complex features into specific, well defined tasks for AI agents
  • Code Review: Critically evaluating AI generated code for quality, maintainability, and alignment with project goals
  • Iterative Refinement: Providing feedback and requesting modifications to achieve the desired outcome
  • Version Control: Managing changes through Git to maintain a clear development history

The project also enhanced my skills in web technologies (HTML5, CSS3, JavaScript), responsive design principles, UI/UX considerations, and Git version control. By treating AI as a collaborative tool rather than a replacement for critical thinking, I developed a workflow that maximises productivity while maintaining high code quality and design standards.

This experience has prepared me for the evolving landscape of software development, where the ability to effectively collaborate with AI tools is becoming as important as traditional programming skills. It demonstrates my adaptability, project management capabilities, and understanding of how to leverage emerging technologies to deliver professional results.

I place strong emphasis on attention to detail throughout design and implementation. The site follows a mobile first approach and has been tested across major mobile browsers (Chrome, Safari, Firefox, Edge) to ensure responsive layouts, readable typography, accessible navigation (ARIA attributes and keyboard support), and correct image handling on small screens.

For users who prefer a paper copy, the site's Print controls (the Print link in the top navigation and the print friendly banner) automatically expand all project tiles and ensure photos are included when printing. This provides an easy way to produce a complete, print optimised version of the portfolio that preserves expanded content and images for offline review.

Live Site: korpie15.github.io
GitHub: View Repository

Turtle Bot Warehousing System

Turtle Bot Warehousing System

Autonomous warehousing robot using ROS and lidar navigation

ROS Lidar 3D Printing

The Turtlebot warehousing robot automates item picking and delivery in warehouses using a scalable system of robots. Initially, a single robot maps the warehouse, creating a static map while avoiding dynamic obstacles like people or forklifts. The system assigns tasks to robots based on proximity and payload capacity, coordinating item retrieval and delivery to a drop off zone. Using lidar, the robots dynamically avoid obstacles, including each other, to maintain efficiency.

My focus was on the payload delivery system, a 3D printed mechanism with a servo driven trap door. Mounted on the top of the robot, it securely carries and dispenses items from the pick up to the drop off zone. Controlled by an Arduino Nano that listens for a signal from the Raspberry Pi the turtle bot is running on. By being mounted above the Lidar the system minimises interference with the lidar for smooth operation.

GitHub: View Repository

Robotics Control Project

Robotics Control Project

Pick, place, and sorting system with custom kinematics

Kinematics RealSense Computer Vision

This project involved simulating a robotic system with two robots, one of which required designing both its physical and kinematic models. The system was tasked with performing a pick, place, and sorting operation to organise blocks by colour. This included a GUI, obstacle detection, and a physical emergency stop button that worked in both simulation and on real hardware. A RealSense camera was used for vision, providing both colour and depth data.

Through this project, I gained a deeper understanding of robotics mathematics, including kinematics and singularity errors. This insight connected theory to my practical experience as a control systems engineer, where I had recently encountered similar challenges with Fanuc robots. Learning the theory behind why robot joints cannot align straight, to avoid singularity errors, was particularly valuable as it directly addressed a real world problem I had faced.

AI Tetris

AI Tetris

Deep Q Network AI that plays Tetris using reinforcement learning

Deep Learning DQN Python

In AI in Robotics, my group project was to program an AI model that could play Tetris. We successfully achieved this goal.

The Tetris AI project uses Deep Q Networks (DQN) and reinforcement learning to optimise gameplay. The AI evaluates the best moves based on board metadata, enabling it to plan for combos like "Tetris clears" while minimising gaps and towers. It generalises well across board sizes, such as a 30x20 grid, despite training exclusively on a standard 10x20 grid. By analysing final states instead of individual moves, the model achieves efficient, adaptable, and high-performing gameplay.

Live Demo: Play Tetris AI
GitHub: View Repository

SPOT Search and Rescue

SPOT Search and Rescue

Boston Dynamics SPOT with autonomous exploration and YOLOv3

ROS YOLO Autonomous Navigation

This group project involved leveraging the Boston Dynamics SPOT robot for search and rescue operations in challenging and potentially hazardous environments. We developed a ROS1 package to facilitate autonomous exploration and human detection, making the system accessible for anyone to install and use. The onboard video feed from SPOT was integrated with YOLOv3 for human identification, achieving a confidence threshold of 80%. Since the pre trained human detection model met our needs, no additional model training was required. When a human was detected, a marker was placed on a global map, allowing rescuers to pinpoint their exact locations.

Exploration of the environment utilised a greedy frontier based algorithm, ensuring complete area coverage. Once SPOT finished exploring, the total number of markers on the map provided the rescue team with a clear overview of all detected individuals and their locations.

This project was also a significant learning experience for me. It marked my first exposure to ROS, Linux, and Git repositories, helping me build confidence in installing and integrating different packages into robotic projects. These new skills have expanded my technical capabilities and prepared me for future projects.

THOR Robot

THOR Robotic Build

Open source humanoid robot build for UTSMechSoc

Robotics Hardware Open Source

Open source humanoid robot build project for UTSMechSoc to engage members and showcase at open days.

The THOR robot project was undertaken as a society initiative to provide hands on learning opportunities for members while creating an impressive display piece for university events. This open source build allowed students to gain practical experience in mechanical assembly, electrical systems, and robotics integration.

THOR Robot

Professional Capabilities

Technical Skills

Control Systems Design and Programming
PLC Programming (Siemens, Ladder Logic)
Experience with Siemens and SEW Drives
Robotics Programming (Fanuc, Roboguide)
CAD Design and Development
Experience in Factory Acceptance Testing (FAT) and Commissioning

Soft Skills

Leadership Team Management Communication Project Management Problem Solving Innovation Collaboration Adaptability Critical Thinking Mentorship

Get In Touch

I'm always interested in new opportunities and collaborations. Feel free to reach out!

Download Resume