A selection of electronic design projects I've completed across different industries and applications. From concept to production.
Industrial Monitoring System: Achieving ±0.1% Accuracy in Harsh Environments
The Challenge: An industrial automation company needed a measurement system that could handle both voltage (0-30V) and current (4-20mA) signals with extreme precision, while surviving electrical noise and transient spikes in factory environments.
The Solution: A dual-channel analog measurement board was designed with dynamic gain configuration, complete galvanic isolation, and military-grade transient protection. The intelligent design allows field reconfiguration without hardware changes.
Results: The system now monitors critical processes with exceptional reliability, reducing false alarms and enabling predictive maintenance that saves thousands in downtime costs.
Similar Challenge? If you need precision measurement in industrial environments, let's talk.
Precision Dispensing: From 50mm to 10mm Detection Range
The Challenge: A medical device manufacturer needed ultra-precise fluid level sensing for their automated dispensing system. Standard ultrasonic sensors couldn't detect fluids closer than 50mm - but their application required accurate measurement down to 10mm.
The Solution: A custom dual-transducer ultrasonic sensor was engineered using high-frequency transducers and proprietary signal processing algorithms. The innovation was in overcoming the "blind zone" that plagues conventional sensors.
Results: The system now achieves 5x better minimum detection range, eliminating waste and enabling more compact device design. Production yield improved significantly by catching low-level conditions earlier.
Need Custom Sensors? Salitronic specializes in solving "impossible" sensing challenges.
Wearable Activity Monitor: 12-Month Battery Life Achieved
The Challenge: A health-tech startup needed a wearable sensor that could monitor multiple physiological parameters continuously for an entire year on a single coin cell battery - while maintaining reliable Bluetooth connectivity and storing weeks of data.
The Solution: An ultra-low-power BLE sensor was designed around the Nordic nRF52832, featuring a custom PCB trace antenna, IMU, flash memory, and multi-sensor interface. Advanced power management and intelligent sampling algorithms were key to achieving exceptional battery life.
Results: The device exceeded the 12-month battery life target, enabling the client to launch their product on schedule. The integrated PCB antenna eliminated external components, reducing BOM costs by 30% while maintaining excellent wireless performance.
Building a Wearable? Battery life and size constraints can be overcome with the right design approach.
High-Power Converter: 60% Space Reduction with Thermal Innovation
The Challenge: An equipment manufacturer needed a high-power boost converter with dual CC/CV modes for a space-constrained industrial application. Off-the-shelf solutions were either too large, too expensive, or lacked the precise control they required.
The Solution: A custom switching power supply was designed with firmware-selectable constant current and constant voltage modes, paired with a precision-engineered bent aluminum heatsink. The thermal design allowed high power density while maintaining safe operating temperatures in the tight enclosure.
Results: The integrated design reduced system volume by 60% compared to commercial alternatives, enabling a more compact product design. Custom firmware control delivered the exact power profiles needed, eliminating complex external control circuitry.
Space Constraints? High power density thermal design is a specialty.
Solar Pump System: 24/7 Operation with 95% Uptime in Remote Locations
The Challenge: An agricultural technology company needed a solar-powered pumping system that could operate reliably in remote locations with no grid access. The system had to maximize solar harvest, provide backup power during cloudy periods, and enable remote monitoring from anywhere.
The Solution: A high-power solar converter was engineered with advanced MPPT control, integrated Li-Ion battery management, and cellular connectivity. The intelligent power management system automatically optimizes between solar, battery, and pump operation to ensure continuous water delivery.
Results: The system achieves 95%+ uptime even during variable weather conditions. Remote monitoring via cellular reduced maintenance visits by 80%, saving significant operational costs. Farmers can now monitor and control their irrigation from their smartphones.
Off-Grid Application? Renewable energy systems can be designed to just work reliably.
Agricultural IoT: Years of Battery Life from Sunlight Alone
The Challenge: An agtech company needed field-deployable crop monitoring sensors that could operate for years without maintenance in remote agricultural settings. The sensors needed to track multiple environmental parameters and transmit data over cellular IoT networks - all while being completely solar-powered.
The Solution: An ultra-low-power control board was developed around the STM32L433 ARM Cortex microcontroller with extreme power optimization. The system features solar charging with MPPT control for a small LiPo battery, and intelligent sleep/wake cycles that reduce power consumption to microamps between readings.
Results: The sensors achieve multi-year operation on harvested solar energy alone, even during winter months. The cellular IoT connectivity provides real-time crop data to farmers, enabling data-driven decisions that have improved yields while reducing water and fertilizer use.
Need Ultra-Low Power? Energy harvesting IoT designs are a specialty.
Smart Building System: Reducing Asset Search Time by 90%
The Challenge: A facility management company was losing hours daily searching for mobile equipment and assets across large buildings. They needed a real-time tracking solution that could integrate seamlessly with existing network infrastructure without complex installation or battery maintenance.
The Solution: A PoE-powered asset monitor was designed that leverages existing network cabling for both power and data. The device features BLE detection for tracking wireless tags, onboard processing for intelligent filtering, and seamless integration with building management systems - all with simple plug-and-play installation.
Results: Asset search time dropped by 90%, freeing staff for more productive work. The PoE design eliminated installation costs and battery maintenance. Inventory accuracy improved dramatically, preventing duplicate purchases and reducing equipment losses.
Building Automation Project? Intelligence can be integrated into existing infrastructure.
Compact 2kV Inverter: 70% Size Reduction Through Modular Design
The Challenge: A scientific equipment manufacturer needed a high-voltage inverter capable of generating precise, variable-frequency sinusoidal waveforms up to 2kV from low-voltage DC sources. Space was extremely limited, and the design needed to be scalable for different voltage requirements without complete redesigns.
The Solution: A cascaded modular inverter architecture was developed that allows voltage scaling through stackable stages. Advanced power electronics and thermal optimization enabled exceptional power density, while precise digital control ensures clean sinusoidal output with variable frequency capability.
Results: The modular design reduced system volume by 70% compared to traditional linear approaches and 40% versus competing switching designs. The scalable architecture enabled the client to serve multiple product variants from a single platform, reducing development costs and time-to-market for new configurations.
High-Voltage Challenge? Complex power requirements can be turned into compact solutions.
Arctic Battery System: Enabling -40°C Operation with Smart Heating
The Challenge: An environmental monitoring system needed to operate reliably in extreme cold climates down to -40°C. The heating solution had to wrap around the battery compartment, provide uniform heating without hot spots, and integrate with the device's power management for intelligent thermal control.
The Solution: A flexible PCB heater was designed with precision-engineered heating traces on one side and an optimized heat spreader layer on the other. The flex design conforms to the enclosure geometry while delivering uniform temperature distribution. Integration with the device's PID controller enables intelligent, energy-efficient warming.
Results: The monitoring system now operates reliably in Arctic conditions, enabling year-round environmental data collection in remote locations. The flex design reduced installation complexity and improved heating uniformity by 85% compared to wire-based heaters, protecting sensitive electronics and batteries from cold-weather damage.
Extreme Environment Application? Thermal solutions can be designed to adapt to specific constraints.
High-Precision RTK GNSS/IMU Tracker: Centimeter-Level Positioning
The Challenge: A client needed a compact, high-precision positioning system capable of centimeter-level accuracy for mobile applications. The solution required RTK-capable GNSS, inertial measurement for dead reckoning during signal loss, and wireless data connectivity.
The Solution: A custom tracker board was designed around the u-blox NEO-M8P RTK GNSS module paired with the BNO055 9-axis IMU featuring onboard sensor fusion for inertial navigation. A dedicated ATSAM high-performance microcontroller handles real-time sensor processing and data fusion, while the ESP32-S3 manages Wi-Fi/Bluetooth networking. A Taoglas active GNSS antenna with LNA ensures excellent signal reception, while UHF connectivity enables RTK correction data. LiPo battery power with USB-C charging makes it fully portable.
Results: The integrated design delivers centimeter-level positioning accuracy in a compact, portable form factor. The dual-MCU architecture separates real-time sensor processing from networking tasks, ensuring deterministic performance. The BNO055's onboard sensor fusion provides orientation and position continuity during GNSS outages.
Precision Positioning Project? High-accuracy GNSS and sensor fusion designs are a specialty.
Multi-Channel TEC Controller: Precision Temperature Regulation
The Challenge: A client required precise temperature control for multiple thermoelectric cooler (TEC) modules in a laboratory instrument. Each channel needed independent regulation with high efficiency and the ability to both heat and cool.
The Solution: A 3-channel TEC controller was designed with dedicated synchronous buck converters for each channel, enabling efficient bidirectional current control. The microcontroller implements independent PID loops for each TEC module, with screw terminals for easy connection to TEC elements and temperature sensors. Multiple power stages handle the substantial current requirements of TEC modules.
Results: The controller provides stable, precise temperature regulation across three independent zones. The synchronous topology maximizes efficiency and minimizes heat generation in the driver circuitry itself. Modular design allows scaling to additional channels as needed.
Thermal Control Application? Precision temperature management systems can be engineered for your requirements.
Miniature Wearable Battery Module: Safe, Compact Power
The Challenge: A wearable device manufacturer needed extremely compact battery modules with integrated charging and protection circuitry. The modules had to be small enough for wearable applications while providing safe, reliable power with USB-C charging capability.
The Solution: Tiny battery modules were designed that integrate a small LiPo cell with complete charging and protection circuitry on a minimal PCB footprint. USB-C connectivity provides modern charging compatibility. The integrated protection circuitry guards against overcharge, over-discharge, and overcurrent conditions.
Results: The ultra-compact modules enable wearable designs that were previously impossible due to battery system size constraints. Safe, standardized USB-C charging eliminates the need for proprietary chargers, improving user experience.
Wearable Power Challenge? Compact, safe battery solutions can be designed for any form factor.
Ultra-Compact nRF52 Multi-Sensor Board: Maximum Sensing in Minimum Space
The Challenge: A client needed a miniaturized wireless sensor platform capable of monitoring multiple environmental and motion parameters in a space-constrained application. The design had to integrate multiple sensors with BLE connectivity on the smallest possible footprint.
The Solution: A highly integrated mini board was designed around the Nordic nRF52832 SoC, packing multiple sensors onto a compact PCB. The design includes USB-C for charging and programming, with careful layout optimization to minimize board size while maintaining signal integrity and RF performance.
Results: The ultra-compact design delivers multi-sensor capability in a form factor small enough for previously impossible applications. The nRF52832's low power consumption enables extended battery life despite the minimal board size.
Need Miniaturized Sensing? Complex sensor systems can be packed into remarkably small packages.
Industrial i.MX Single-Board Computer: Rugged SCADA Platform
The Challenge: An industrial automation client needed a rugged single-board computer for SCADA applications with high-performance processing, multiple connectivity options, and long-term availability. The platform had to support Linux with real-time capabilities and industrial-grade reliability.
The Solution: A custom SBC was designed around the NXP i.MX processor with DDR memory, featuring dual Ethernet ports, multiple USB interfaces, and expansion headers for application-specific I/O. Robust power management handles wide input voltage ranges and industrial transients. The design prioritizes component longevity and thermal performance.
Results: The platform provides a reliable foundation for industrial SCADA deployments with the processing power to run modern HMI applications. Dual Ethernet enables network redundancy, while the expansion capability allows customization for specific industrial protocols.
Industrial Computing Project? Rugged, long-lifecycle embedded platforms can be designed for demanding environments.
BLE Motion-Activated Remote: Gesture-Triggered Wireless Control
The Challenge: A client needed a custom wireless remote control that activates on motion detection, eliminating the need for button presses to wake the device. The design had to fit a specific enclosure shape while providing reliable BLE connectivity and extended battery life.
The Solution: A custom-shaped PCB was designed around the Texas Instruments CC2640 BLE SoC with integrated motion sensing for wake-on-movement functionality. The board features a PCB trace antenna optimized for the enclosure, with an additional RF connector for testing. A tactile button provides manual input, while the motion sensor enables instant-on operation when the remote is picked up.
Results: The motion-activated wake feature dramatically improves user experience by eliminating the button press to wake the device. The custom PCB shape fits the enclosure perfectly, maximizing internal space for the battery while maintaining excellent RF performance.
Custom Remote Design? Wireless controls can be engineered to fit any form factor and user interaction model.
Multi-Chip Wireless Module: Bio-Medical Signal Acquisition in a Compact Package
The Challenge: A medical device company needed a wireless module capable of acquiring and transmitting multiple bio-medical signal channels simultaneously. The design had to fit in an extremely compact form factor while maintaining signal integrity across multiple high-speed digital interfaces.
The Solution: A densely integrated module was engineered featuring multiple QFN-packaged ICs including a wireless SoC, analog front-end, and dedicated signal processor. The 4-layer PCB design carefully manages signal routing between chips, with a u.FL connector for external antenna options. Precise impedance control ensures reliable high-speed communication between all components.
Results: The module delivers medical-grade signal acquisition in a package smaller than a postage stamp. The multi-chip architecture provides the processing power needed for real-time signal analysis while the optimized layout maintains excellent signal integrity.
Compact Wireless Design? High-density multi-chip designs can be engineered for demanding applications.
Multi-Sensor IoT Gateway: Complete Environmental Intelligence
The Challenge: A smart building company needed an all-in-one sensor platform that could monitor air quality and environmental conditions while communicating over sub-GHz networks for long-range coverage. The device needed to be self-contained with easy deployment.
The Solution: A stacked PCB architecture was developed within a compact enclosure, integrating PIR motion detection, temperature and humidity sensors, NOx and particulate matter detectors, and a helical sub-GHz antenna for long-range communication. The clear enclosure allows visual confirmation of operation while the modular internal design enables sensor customization per deployment.
Results: The gateway provides comprehensive environmental intelligence from a single installation point. Air quality data combined with occupancy and climate monitoring enables intelligent HVAC control and healthier indoor environments.
Smart Building Project? Integrated sensor platforms can provide the data foundation for intelligent automation.
Precision RGB Driver: Laboratory-Grade Color Accuracy in Your Hand
The Challenge: A medical device company needed an RGB LED driver for a handheld diagnostic instrument that required exceptional color accuracy and stability. The driver had to fit in an extremely slim form factor while delivering precise, repeatable color output for reliable diagnostic readings.
The Solution: A high-precision analog LED driver was designed with dedicated current regulation for each RGB channel. Low-noise linear regulators and precision feedback ensure color stability across temperature variations. The slim elongated PCB fits perfectly along the instrument housing while keeping thermal effects away from sensitive optics.
Results: Color accuracy meets laboratory calibration standards, enabling reliable diagnostic readings. The analog design eliminates PWM flicker that could interfere with optical measurements, while the slim form factor integrates seamlessly into the handheld enclosure.
Precision Lighting Application? Custom LED drivers can achieve accuracy levels impossible with standard modules.
Integrated Motor Driver: Precision Motion in a Tiny Package
The Challenge: A medical device company needed a compact motorized actuator for a handheld instrument. The motor driver had to fit within the device housing, provide precise speed control, and integrate seamlessly with the existing mechanical assembly.
The Solution: A custom-shaped PCB was designed around the TI DRV8833 dual H-bridge driver, matching the contours of the enclosure. The board integrates an STM32 microcontroller for closed-loop speed control, with the motor mounted directly to the PCB assembly. The shaped board maximizes use of available space while providing all necessary drive and control functionality.
Results: The integrated design eliminated separate motor driver modules and wiring harnesses, reducing assembly time and improving reliability. Firmware-based speed control provides smooth, precise actuation exactly matched to the application requirements.
Compact Actuator Design? Custom motor driver integration can optimize both performance and manufacturability.
TEC Liquid Cooler Driver: Precision Temperature Control for Cooling Systems
The Challenge: A laboratory equipment manufacturer needed a driver board for a TEC-based liquid cooling system capable of precise temperature control. The design required high-current drive capability, bidirectional operation for heating and cooling, and integration with existing control systems.
The Solution: A high-current TEC driver was designed with H-bridge topology for bidirectional current flow, enabling both cooling and heating modes. Precision current sensing enables accurate power control, while robust terminal blocks handle the high currents required for effective thermal management. A WiFi-enabled microcontroller implements PID temperature control with remote monitoring and adjustment.
Results: The cooling system achieves precise temperature regulation within ±0.1°C of setpoint. The bidirectional capability enables rapid temperature transitions, while WiFi connectivity allows remote temperature monitoring and control from any device.
Precision Cooling Application? TEC-based systems can achieve temperature control impossible with conventional methods.
Wireless Industrial Controller: Remote Switching Without Wires
The Challenge: A facility management company needed to remotely control equipment in locations where running new control wiring was impractical or prohibitively expensive. The solution had to work reliably in industrial RF environments while switching significant loads.
The Solution: A sub-GHz wireless controller was designed with a helical antenna for excellent range and penetration through industrial structures. The board features a relay for direct load switching, safety-rated capacitors for reliable operation, and screw terminals for easy field installation. An SMA connector allows external antenna connection for extended range applications.
Results: Equipment that was previously manually operated can now be controlled remotely, improving operational efficiency and enabling automated scheduling. The sub-GHz frequency provides reliable communication even in challenging RF environments where 2.4GHz WiFi struggles.
Remote Control Application? Industrial wireless solutions can eliminate wiring while maintaining reliability.
Stretchable PCB: Electronics That Flex and Stretch
The Challenge: A wearable technology company needed electronics that could not only bend but actually stretch with body movement. Traditional flex PCBs crack when stretched, limiting their use in applications requiring true conformability to dynamic surfaces.
The Solution: A stretchable PCB was developed using specialized materials and serpentine trace geometries that accommodate elongation without breaking. The design places rigid components in islands connected by stretchable interconnects, allowing the overall assembly to stretch while protecting sensitive parts.
Results: The stretchable design achieves up to 30% elongation while maintaining electrical connectivity. This enables truly conformable electronics for wearables, soft robotics, and medical devices that move with the user rather than against them.
Stretchable Electronics Need? Advanced PCB materials can enable applications impossible with conventional flex circuits.
Custom RGB LED Strip: Precision Lighting with Full Color Control
The Challenge: An architectural lighting designer needed custom LED strips with specific dimensions, LED spacing, and mounting options that weren't available from standard products. The strips needed individually addressable LEDs for dynamic lighting effects.
The Solution: Custom PCB strips were designed with dual rows of addressable RGB LEDs, providing high light output with full individual pixel control. The white solder mask maximizes light reflection, while the specific board dimensions and mounting hole pattern match the installation requirements exactly.
Results: The custom strips integrate perfectly into the architectural design, with the exact length and mounting pattern needed. The addressable LEDs enable stunning dynamic effects that transform the space, while the dual-row configuration provides the light output required.
Custom Lighting Project? Purpose-built LED solutions can achieve effects impossible with off-the-shelf products.
Custom ESP WiFi Module: Tailored Connectivity Platform
The Challenge: A product developer needed WiFi connectivity but found that standard ESP modules didn't fit their form factor requirements or provide the specific I/O configuration needed. A custom solution was required that maintained the ease of ESP development while optimizing for the application.
The Solution: A custom board was designed around the ESP32 chip with ISSI flash memory for program storage. The PCB includes an optimized trace antenna, JST connectors for battery and peripheral connections, and all necessary support circuitry. The layout maintains RF performance while fitting the required enclosure.
Results: The custom module provides all the WiFi capability and development ecosystem benefits of ESP while perfectly matching the product requirements. Unnecessary features were eliminated, reducing cost and board space, while critical I/O was positioned for optimal cable routing.
Custom WiFi Integration? Application-specific wireless modules can optimize both performance and cost.
Isolated Analog Interface: Precision Signal Transfer Across Isolation Barriers
The Challenge: An industrial automation company needed to transmit precision analog signals across high-voltage isolation barriers without sacrificing accuracy. Standard digital isolation introduced quantization errors, while transformer-coupled solutions couldn't handle DC signals.
The Solution: A multi-channel isolated analog interface was designed using linear optocouplers that maintain analog signal fidelity across the isolation barrier. Each channel features matched LED-photodiode pairs with servo feedback for exceptional linearity. The numbered channel layout simplifies installation and troubleshooting.
Results: The interface achieves better than 0.1% linearity while providing thousands of volts of galvanic isolation. DC to medium frequency signals pass through without the artifacts of digital conversion, enabling precision measurement in high-voltage industrial environments.
Isolated Analog Requirement? Linear optocoupler interfaces can bridge isolation barriers without compromising signal integrity.
Smart NFC Belt Sensor: Wireless Conveyor Damage Detection
The Challenge: A mining equipment company needed a way to detect conveyor belt damage before catastrophic failure. The sensors had to be embedded within the belt itself, operate without batteries, and survive the harsh flexing and impact environment of industrial conveyors.
The Solution: A flexible polyimide PCB sensor was designed to harvest power wirelessly via NFC from reader stations along the conveyor path. The board integrates a low-power microcontroller with strain sensing capability, transmitting belt condition data back through the same NFC link. The slim profile allows embedding within belt layers.
Results: Belt failures that previously caused hours of unplanned downtime are now detected early, enabling scheduled maintenance. The battery-free design eliminates maintenance of the sensors themselves, while the flexible construction survives millions of flex cycles.
Industrial Sensing Challenge? Embedded wireless sensors can monitor equipment health in previously impossible locations.
Ultra-Compact BLE Board: Maximum Capability, Minimum Size
The Challenge: A medical device company needed Bluetooth connectivity in an implant-grade form factor where every cubic millimeter mattered. Standard BLE modules were too large, but designing from scratch would require expensive RF certification.
The Solution: A minimal carrier board was designed for the Rigado BMD-300 module, which provides pre-certified BLE 5.0 capability based on the Nordic nRF52 in an extremely compact package. The carrier adds only essential support components, resulting in a complete BLE solution barely larger than the module itself.
Results: The design achieves BLE connectivity in a fraction of the space required by typical solutions. Using the pre-certified module dramatically reduced time to market and certification costs while the custom carrier optimizes the specific I/O and form factor requirements.
Size-Critical Wireless? Pre-certified modules with custom carriers can achieve optimal size and time-to-market.