Autonomous Coastal Water Quality Monitoring
A solar sensor node, a LoRa backhaul requiring no cellular contract, and a dashboard reviewed by an operations team before crews leave the dock.
Hardware Design and Product Development Services
We develop custom hardware from initial requirements through PCB design, firmware, enclosure design, prototyping, testing, and manufacturing handoff.
Challenges We Solve
The things that stall a hardware project, and what we do about each one.
Prototype Designs That Are Not Ready for Manufacturing
A functional prototype may still require changes to support reliable assembly, testing, sourcing, and production. We include design for manufacturing and test requirements throughout development.
Component Availability and Lifecycle Risk
We evaluate component availability, lead times, lifecycle status, and alternatives before finalizing the design and bill of materials.
Late Thermal and Mechanical Issues
PCB dimensions, component placement, heat dissipation, connectors, and enclosure requirements are developed together to identify integration issues before tooling or production.
Missing Production Test Procedures
We define functional test requirements, test points, procedures, and fixtures so production units can be verified consistently.
Coordination Across Multiple Engineering Suppliers
Electrical, firmware, and mechanical engineering are managed through one project team with shared requirements, schedules, and design reviews.
Our Hardware Services
Integrated electrical, firmware, and mechanical engineering for custom hardware products, from initial design through manufacturing preparation.
- PCB Design ServicesPart selection, schematic capture, multi-layer PCB layout, controlled impedance, power distribution, design review, and preparation of fabrication and assembly files.
- Product Development PrototypingFunctional prototypes for feasibility testing, engineering validation, user evaluation, demonstrations, and design refinement before production release.
- 3D Printing and FabricationIn-house SLA and FDM printing for fit checks, functional prototypes, test fixtures, custom components, and short-run parts using materials selected for the test requirements.
- CAD and Enclosure DesignMechanical architecture, enclosure CAD, tolerance analysis, thermal design, material selection, assembly details, and production drawings.
- Embedded FirmwareBoard bring-up, device drivers, communications, control logic, diagnostics, bootloaders, secure field updates, and embedded test support.
- Design for Manufacture and TestPanelization, test access, assembly documentation, production programming, functional test procedures, and manufacturing support.
Benefits of One Hardware Team
The difference it makes to your schedule, your bill of materials, and what you own at the end.
Integrated Project Delivery
Electrical, firmware, and mechanical work follows one set of requirements, milestones, and review points.
Complete Design Ownership
Clients receive editable schematics, PCB layouts, CAD files, firmware source, and production documentation.
Lower Redesign Risk
Early feasibility work and staged prototyping identify technical issues before the design reaches production.
More Reliable Component Sourcing
Bills of materials include availability checks, lifecycle review, and alternatives for critical components.
Repeatable Manufacturing
Production packages include fabrication data, assembly information, test points, and documented test procedures.
Certification Readiness
Electrical spacing, emissions, power, thermal, and enclosure requirements are considered before formal compliance testing.
How We Work
Four stages, each ending in something you can review and a decision you can actually make.
Concept and Feasibility
Define product requirements, operating conditions, interfaces, compliance needs, target cost, production volume, and the technical risks that require early validation.
Detailed Design and Engineering
Develop schematics, PCB layouts, firmware architecture, enclosure models, and a bill of materials reviewed for availability, lifecycle, and lead time.
Prototyping and Iteration
Build and test engineering prototypes, document results, correct identified issues, and complete the design revisions required for the next validation stage.
Testing and Refinement
Verify the design against approved requirements, complete pre-compliance testing where applicable, and prepare the production and test documentation for manufacturing handoff.
Every node on the track is a gate. At each one you can carry on, change the scope, or take the design files and go elsewhere. You're never committing to the whole thing at once.
Hardware Applications
Hardware development for connected, industrial, portable, commercial, and regulated products.
Connected Sensors and Instrumentation
Sensor interfaces, signal conditioning, calibration, data acquisition, embedded processing, and device connectivity.
Environmental and Remote Monitoring
Low-power electronics, wireless communications, outdoor enclosures, remote updates, and long-term field operation.
Industrial and Control Electronics
Embedded controllers, wired communications, machine interfaces, power electronics, and designs for electrically noisy environments.
Battery-Powered and Portable Devices
Power budgeting, battery selection, charging, low-power firmware, compact electronics, and portable enclosure design.
Consumer and Commercial Products
Custom electronics and enclosures developed around usability, appearance, reliability, production cost, and service requirements.
Certified and Regulated Products
Products developed for applicable electrical safety, electromagnetic compatibility, wireless, environmental, and industry-specific requirements.
Why Work With Us
Four commitments we make on every hardware engagement.
Integrated Hardware Engineering
PCB design, firmware, enclosure design, prototyping, and manufacturing preparation are handled by one project team.
Client Ownership
Editable design files and source code transfer to the client according to the project agreement.
Prototype-Based Validation
Technical uncertainty is addressed through calculations, simulations, focused prototypes, and documented testing.
Manufacturing-Focused Decisions
Materials, tooling, assembly methods, test requirements, and production volume are considered during design.
Hardware Engagement Models
Choose a focused design review, a complete product-development program, or additional engineering capacity for an existing team.
Design Review
An independent review of schematics, PCB layout, bill of materials, firmware interfaces, enclosure constraints, and manufacturing readiness, with findings ranked by risk.
Best for an existing design before prototype or production release.
Full Product Development
Complete product development from requirements and feasibility through design, prototyping, validation, and manufacturing handoff, managed through defined milestones.
Best for new hardware products or substantial redesigns.
Engineering Capacity
Additional electrical, firmware, or mechanical engineering capacity assigned to a defined workstream within the client's existing development process.
Best for teams that need additional technical capacity or specialized expertise.
Common Questions
The things people ask us on the first call, answered the way we'd answer them on the phone.
Can you pick up a design someone else started?
Yes. We usually begin with a design review covering the available schematics, PCB files, firmware, mechanical files, bill of materials, test results, and production documentation. The review identifies what can be retained, what requires revision, and the recommended next steps.
Who owns the design files?
The client owns the completed project files according to the project agreement. Handover includes editable schematics, PCB layout, mechanical CAD, firmware source, and applicable production documentation rather than exported files alone.
What production volumes do you design for?
Our typical work covers production volumes from hundreds to low hundreds of thousands of units. The appropriate enclosure, assembly, tooling, and test strategy depends on expected volume, target cost, product life, and service requirements.
Do you handle certification?
We design for applicable certification requirements, perform available pre-compliance testing, prepare technical documentation, and support formal testing through an accredited laboratory. Formal certification is issued by the laboratory or relevant authority.
Can you build the software side too?
Yes. Our software team can develop the device services, APIs, web applications, mobile applications, dashboards, and cloud infrastructure associated with the hardware. See Software Development.
Selected Work
Boards, the firmware running on them, and the systems they report to, written up with the constraints as well as the outcome.
Hardware is one of four service areas
Sunlab coordinates hardware, software, AI, and marketing within one delivery team. This reduces handoff delays, clarifies responsibility for cross-disciplinary decisions, and provides one point of contact.
SoftwareCustom web, mobile, platform, and internal software developed around defined business and user requirements.View the ServiceAIAI products and workflows built around a defined use case, the right data, measurable performance, and a responsible path to production.View the ServiceMarketingMarket research, positioning, websites, search, content, campaigns, and analytics for technical products and services.View the Service
Start a Hardware Engagement
Send us the product requirements, available design files, target production volume, operating conditions, and current technical questions. We will recommend an appropriate first phase.
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