Portfolio & Case Studies
Selected projects from our portfolio of high-reliability designs
Aerospace Power Distribution Board Redesign
Context
A tier-1 aerospace supplier needed to modernise a legacy power distribution board for next-generation avionics. The original design was reliable but used obsolete components and lacked EMC margin for new RF environments.
Constraints
DO-254 compliance required, thermal management in confined avionics bay, component obsolescence mitigation, zero re-spin tolerance, 18-month qualification timeline.
Our Responsibility
Full schematic redesign, component selection and derating, PCB layout with EMC considerations, SI/PI analysis, and DFM package development.
Outcome
Delivered production-ready design with improved thermal performance, 40% reduction in component count, and first-pass EMC compliance. Avoided costly re-spin and accelerated time-to-market by 6 months.
Mixed-Signal Sensor Interface for Industrial Control
Context
An industrial automation company required a high-precision sensor interface for a safety-critical process monitoring system. Existing design suffered from noise coupling and EMI susceptibility in factory floor environments.
Constraints
IEC 61508 SIL 2 compliance, 0.1% measurement accuracy, operation in high-EMI industrial environment, compact form factor, cost-sensitive production.
Our Responsibility
Analogue front-end redesign, low-noise PCB layout, shielding strategy, signal conditioning circuit optimisation, and EMC pre-compliance testing coordination.
Outcome
Achieved 10x improvement in noise immunity, passed EMC testing on first attempt, and reduced BOM cost by 15% through optimised component selection. System now operates reliably in harsh industrial environments.
