The Challenge
In industrial security applications, size and complexity can be the enemy of effective deployment. Our client needed to optimize their main control board, a sophisticated embedded Linux platform managing BGA MPUs, DDR2 SRAM, eMMC flash, multiple Ethernet ports, RS-485 communications, industrial I/Os, and PoE power systems.
The goal was creating deployable, manufacturable security solutions without compromising functionality.
Our Solution
We approached this as both a design and manufacturing challenge, leveraging our deep understanding of industrial requirements and production realities:
Strategic Layout Optimization: We reimagined the PCBA design, reducing the PCB stack from eight layers to six while maximizing component placement efficiency on both board sides.
Size Reduction Success: Achieved 50% reduction in overall PCBA footprint, enabling deployment in compact housings critical for security applications.
Enhanced Testing Infrastructure: Developed comprehensive In-circuit Test (ICT) and Functional Test (FCT) programs that improved test coverage while reducing production cycle times.
Results That Secure Success
- Five similar projects completed over 12 months, demonstrating repeatable excellence
- EVT samples delivered and passed CE certification within eight weeks per project
- 50% size reduction enabling deployment in space-constrained security installations
- Improved manufacturing efficiency through optimized design and enhanced testing protocols
