Hardware Design and Product Development Services
We develop custom hardware from initial requirements through PCB design, firmware, enclosure design, prototyping, testing, and manufacturing handoff.
Our Hardware Services
PCB Design Services
Part selection, schematic capture, multi-layer PCB layout, controlled impedance, power distribution, design review, and preparation of fabrication and assembly files.
Embedded Firmware
Board bring-up, device drivers, communications, control logic, diagnostics, bootloaders, secure field updates, and embedded test support.
CAD and Enclosure Design
Mechanical architecture, enclosure CAD, tolerance analysis, thermal design, material selection, assembly details, and production drawings.
3D Printing and Fabrication
In-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.
Design for Manufacture and Test
Panelization, test access, assembly documentation, production programming, functional test procedures, and manufacturing support.
Product Development Prototyping
Functional prototypes for feasibility testing, engineering validation, user evaluation, demonstrations, and design refinement before production release.
How We Work
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.
How We Work
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.
Hardware Applications
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.
Hardware Engagement Models
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
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.
Don’t see your question? Ask Sunlab, the assistant on this page, or email the team.
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.
Ready to Launch Your Next Hardware Product?
Partner with Sunlab Digital to transform your ideas into tangible, high-performing hardware. Get started with a consultation today.
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