The Challenge

A manufacturer relied on an electronic control board that had been in production for several years. While the product itself continued to meet customer requirements, maintaining production became increasingly difficult. The engineering team encountered several challenges:

• Critical integrated circuits reached End-of-Life (EOL).

• Long lead times delayed manufacturing schedules.

• Multiple components could only be sourced from a single supplier.

• The existing PCB limited future hardware updates.

• Reliability improvements were required before the next production run.

  
  

Without intervention, production delays and increasing procurement costs threatened delivery schedules and customer satisfaction.

Engineering Objectives

HiQED established several goals before beginning the redesign:

• Replace obsolete components with long-term available alternatives.

• Maintain existing product functionality.

• Improve electrical reliability.

• Reduce supply chain dependency.

• Simplify future maintenance and upgrades.

• Preserve compatibility with existing mechanical assemblies whenever possible.

  
  

HiQED's Development Approach

Rather than making isolated component substitutions, the project focused on improving the complete electronic design.

1. Component Lifecycle Review

Every active component was reviewed according to:

• Manufacturer lifecycle status

• Supply availability

• Alternative sources

• Long-term availability

• Cost stability

  
  

Components approaching obsolescence were replaced with modern equivalents wherever possible.

2. Circuit Redesign

Certain portions of the schematic required redesign because direct replacements were not electrically compatible. Engineering activities included:

• Updating power management circuits

• Optimizing switching stages

• Improving protection circuitry

• Increasing design margins

• Reducing unnecessary complexity

  
  

3. PCB Layout Optimization

The PCB was redesigned following modern layout practices. Improvements included:

• Better component placement

• Cleaner return current paths

• Improved grounding strategy

• Reduced EMI susceptibility

• Enhanced thermal performance

• Easier manufacturing and assembly

  
  

Design-for-Manufacturing (DFM) and Design-for-Test (DFT) principles were incorporated throughout the layout process.

4. Supply Chain Risk Reduction

One major objective was reducing dependence on individual suppliers. This was achieved by:

• Selecting industry-standard components

• Avoiding proprietary devices where practical

• Using multiple approved manufacturers

• Choosing packages with broad market availability

  
  

This significantly improved purchasing flexibility during future production.

Design Principles Applied

Throughout the redesign, HiQED focused on several long-term engineering principles.

Modular Architecture

Where possible, functional blocks were separated to simplify future modifications without redesigning the entire system.

Standardized Components

Preference was given to widely available parts that can be sourced from multiple manufacturers.

Reliability Improvements

Additional protection measures and improved power distribution increased operational robustness under demanding conditions.

Future Expandability

The updated design allows future revisions to integrate additional functionality with minimal hardware changes.

Engineering Outcome

Following the redesign, the electronic hardware achieved several important improvements.

Increased Component Availability

The bill of materials now consists primarily of actively manufactured components with multiple sourcing options.

Improved Manufacturability

The updated PCB layout simplifies assembly while reducing manufacturing risks.

Enhanced Reliability

Improved routing, optimized grounding, and updated circuitry contribute to greater long-term stability.

Reduced Supply Chain Risk

Multiple approved component alternatives provide significantly greater purchasing flexibility.

Longer Product Lifecycle

The redesign extends the usable life of the product while reducing future redesign costs.

Key Takeaways

Modern hardware development is no longer only about electrical performance. Successful products must also remain manufacturable throughout their lifecycle. Proactive hardware redesign helps organizations:

• Avoid production interruptions

• Minimize redesign costs

• Improve reliability

• Reduce procurement risks

• Extend product availability

• Simplify future upgrades

  
  

For many products, a well-planned redesign is considerably more cost-effective than developing an entirely new platform.

Conclusion

Electronic hardware must evolve alongside changing component markets. Designs that depend on obsolete or difficult-to-source components expose manufacturers to unnecessary operational and commercial risks. At HiQED, we support companies throughout the entire redesign process. We assist from evaluating existing hardware and selecting replacement components to schematic updates, PCB layout optimization, prototype validation, and production-ready documentation.

By combining sound engineering practices with long-term component strategies, we help businesses build electronics that remain reliable, manufacturable, and ready for the future.

Need to Modernize an Existing Electronic Design?

Whether you're facing obsolete components, redesigning a legacy PCB, improving EMC performance, or preparing a product for long-term manufacturing, HiQED can help. Our hardware development services include:

• Hardware redesign

• Schematic development

• PCB layout design

• Component replacement and lifecycle management

• Design for Manufacturing (DFM)

• Design for Testability (DFT)

• Prototype support

• Production documentation

  
  

Let's build electronics that are engineered for tomorrow—not just today. Book a meeting at: https://www.hiqed.at/book

The Importance of Custom Electronic Hardware Development

Custom electronic hardware development is essential for businesses aiming to stay competitive. The right hardware can enhance product performance and reliability. It can also reduce costs and improve time-to-market.

Understanding Your Needs

Before embarking on a hardware development project, it is crucial to understand your specific needs. This includes identifying the functions your product must perform and the environment in which it will operate.

Collaborating with Experts

Working with experts in electronic hardware development can streamline the process. They can provide insights into the latest technologies and best practices. This collaboration can lead to innovative solutions tailored to your requirements.

Prototyping and Testing

Prototyping is a vital step in the development process. It allows for testing and validation of the design before full-scale production. This phase helps identify potential issues early, saving time and resources.

Certification and Compliance

Ensuring that your product meets industry standards is essential. This includes obtaining necessary certifications. Compliance with regulations can prevent costly delays and enhance market acceptance.

Future-Proofing Your Design

Designing with the future in mind is crucial. This involves selecting components that are not only available today but will also be accessible in the years to come. Future-proofing your design can significantly extend the product lifecycle.

Conclusion

In conclusion, custom electronic hardware development is a complex but rewarding process. By focusing on your specific needs and collaborating with experts, you can create products that stand out in the market. Prototyping, testing, and ensuring compliance are all critical steps in this journey. At HiQED, we are committed to guiding you through every stage of this process.