This case study tracks the evolution of a smart-grid sensor from its first breadboard iteration to a full production rollout.
Phase 1: The Breadboard Prototype
Messy wiring and basic functionality. The goal here was validating the logic, not aesthetics or space efficiency.
Phase 2: The First Custom PCB
The first custom PCB. We reduced the footprint by 60% and integrated the power management circuitry into the main board.
Phase 3: Preparing for Production
Reaching a 10,000-unit run required a complete DFM overhaul. We optimized the design for automated pick-and-place assembly and handed off a production-ready package, so the client's manufacturer could build at volume with minimal variance. (We design and prototype; the client's chosen manufacturer runs the volume production.)