Design is where we earn the rest of the relationship.
Most repair houses stop at troubleshooting. Our design team takes on the harder brief: rebuilding a board whose original manufacturer no longer exists, laying out a new multilayer card from scratch, or re-engineering a panel around parts that are still in supply — from requirement stage through to a fully tested board.
Full-cycle PCB design & layout
Design, layout or modification of any analog or digital PCB — our team works with you from the requirement stage to fully understand your exact specification.
Single, double or multilayer — no fixed limit
No limit on number of layers or board size, and no restriction on component type — through-hole or surface-mounted.
Obsolete & hard-to-find part re-manufacture
We re-design around an equivalent part, matching pin configuration while maintaining or improving on the original functionality.
No minimum order quantity
We support low-volume and prototype production requirements just as readily as full production runs.
100% testing & burn-in before dispatch
Every board we design and manufacture is functionally tested and burned in before it ships.
Instrument overlays & keypad design
The human-facing side of the same panel — front overlays and keypads designed to match the electronics beneath them.
— no restriction
— no minimum
From a rough requirement to a manufacturable board
Not every project arrives as a finished schematic. Often it starts as a functional need, a failing legacy board, or a block diagram on paper. Our concept design service takes that starting point and turns it into a producible, testable card — defining the architecture, selecting currently-available components, and planning the layer stack before a single track is routed.
Because the same engineers design, prototype and later repair these boards, manufacturability and long-term serviceability are considered from the very first decision — not bolted on at the end.
- 1Requirement & feasibilityUnderstanding the function, operating environment, interfaces and constraints of the target application.
- 2Architecture & part selectionBlock-level design and selection of readily-available, long-life components — avoiding obsolescence from day one.
- 3Schematic & layer-stack planningSchematic capture and a stack-up sized to signal, power and cost needs — single, double or multilayer.
- 4Layout, prototype & validationRouting, prototype build, and full functional test & burn-in before the design is released for production.
Every board construction, one design team
From simple single-sided cards to dense high-layer-count interconnects, we design and build across the full range of PCB constructions.
Single, double and multilayer rigid boards up to 24 layers — the workhorse of industrial, defense and commercial electronics.
Flex circuits for tight enclosures, moving assemblies and space-constrained designs where a rigid board won't fit.
Combined rigid and flexible sections in a single board — fewer connectors, higher reliability, and compact 3D packaging.
High-Density Interconnect boards with microvias and fine features for the densest, highest-performance designs.
Recreating the design when the documentation is gone
When an OEM has vanished, drawings are lost, or a board is long out of production, we reconstruct the design from the physical card itself — recovering the schematic, netlist and layout so the board can be repaired, re-manufactured, or improved.
This pairs naturally with our re-manufacture service: once a legacy board is reverse-engineered, we can rebuild it around currently-available components and keep the equipment it serves in operation for years to come.
- 1Board capture & analysisDocumenting the physical board, components and connectivity from the sample provided.
- 2Schematic & netlist recoveryRebuilding the electrical design so the board's function is fully understood and documented.
- 3Re-layout with available partsRe-creating the layout, substituting obsolete components with current equivalents where needed.
- 4Prototype, test & hand-offBuilding and functionally testing the recreated board before production or delivery of the design package.
Hardware and the firmware that runs it — designed together
Beyond the board itself, our team develops the embedded firmware and application software that brings a design to life — microcontroller firmware, control loops, communication stacks and the PC-side tools that configure and monitor the product in the field.
Battery chargers, charge controllers & power conversion
A dedicated design capability in power electronics — from intelligent battery management to high-power IGBT and SMPS-based charging systems, engineered for industrial duty cycles and reliability.
AC & DC Charger Controller Design
Intelligent charge-controller electronics for AC- and DC-input charging systems, managing the full charge profile and protecting the battery across its life.
- Multi-stage charge profiles (bulk, absorption, float)
- AC-input and DC-input charger control
- Voltage, current & temperature regulation
- Protection: over-voltage, over-current, reverse polarity
Battery Management Systems (BMS)
Cell-monitoring and protection electronics that keep a battery pack safe, balanced and long-lived — the intelligence layer between the cells and the charger.
- Per-cell voltage & temperature monitoring
- Active / passive cell balancing
- State-of-charge & state-of-health estimation
- Fault protection & safe disconnect
SMPS-Based Charger Design
Compact, efficient switch-mode power supplies for chargers and power converters, delivering tightly-regulated DC from a wide AC input range.
- High efficiency, low heat, compact footprint
- Wide-input AC to regulated DC conversion
- Feedback-controlled voltage & current
- Suited to chargers and embedded power rails
IGBT-Based Chargers
High-power charging and conversion systems built on IGBT switching for demanding industrial loads where robustness and current capability matter most.
- IGBT switching for high-current output
- Industrial-grade thermal & surge design
- Suited to traction, telecom & heavy industrial charging
- Designed alongside matching control firmware
