Hardware Engineering to Enhance High-Energy Ignition Products for a US-Based Leading Company
Overview
A leading US-based manufacturer of high-energy ignition and flame detection products sought to enhance their existing system designs to reduce BOM costs and support new market applications. ACL Digital engineered an optimized hardware solution with zero-variance layouts, enabling cost-effective product upgrades and streamlined volume manufacturing.
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Challenges
High bill of materials (BOM) cost limiting scalability into new market segments
Existing designs required significant modifications for each product variant, increasing development effort and cost
Dependency on legacy design files posed risks for future upgrades and slowed time-to-market
Solution
- The new design with zero variance in track sizes, pitch, or component footprints to reduce the overall cost of design changes in complete system
- Product design, schematics, Gerber, and BOM for devices
- Design review, PCB layout and Gerber release
- BOM optimization to meet the targeted cost of final product
- Prototype build and bring up testing
- Functional testing using existing product setup
- Design transfer for volume manufacturing of all product variants to customer
Outcomes
- Helped client with the source file which removed the dependency and risks of creating completely new designs for any future upgrades in the product
- BOM cost optimized by 28% to meet the entry pricing for different application segment
