Services
Electrical Design
From schematic to solution, we deliver on design
Today’s electronic devices not only communicate with each other, they also interface with the real world via sensors and actuators. As the world becomes more dependent upon data, custom devices are needed to collect and communicate the data to the user.
Zebulon Solutions has extensive experience in designing PCBAs as well as electronics subsystems, from batteries to radios. We are especially skilled at embedded microcontrollers, sensors, analog, wireless communications, and portable devices. We’ve applied our knowledge across a wide variety of industries: from medical devices to clean-tech, IoT products to industrial controllers.
Services
We have every aspect of your electrical design covered
PCBA Design and Layout
We will work with you to develop electronic systems that align with all business requirements, optimizing designs for technical specification, cost, and availability. We utilize a methodical design process.
- Block diagram creation
- Schematic entry
- Component selection
- PCBA floor planning and layout
- Generate industry standard fabrication and assembly files
Firmware
Modern electronic systems have limited functionality without robust firmware. Our extensive experience in integrating software and hardware create products that offer unique function and value.
- Align architecture with functional requirements
- System test during production
- Integrate with third party libraries
- Target 8/16/32-bit microcontrollers
- Bare metal or RTOS implementations
Trade-off Analysis
Successful product design requires optimizing business requirements, technical realities, costs, and supply chain availability. Effective analysis occurs in the early stages of design, but is useful every time options arise
- Evaluation of requirements
- Consider system design options
- Review component availability
- Configure supply chain
- Estimate production costs
Circuit Simulation and Analysis
Estimating circuit performance early in the design process can shorten product development time. Software tools can lower design risks and reduce development costs.
- Expose potential architecture problems
- Simulate circuit performance
- Determine power budget
- Estimate noise in the circuit
Component Evaluation and Selection
Component selection is more than technical requirements. We take a wholistic approach to ensure components are also available, within cost targets and have a robust supply chain.
- Technical specifications
- Cost
- Lead time
- Sourcing options
- Assembly requirements
- End of Life notices
Specialized Designs
Power Circuit Design
Electronics require a reliable power source, from a simple single-voltage wall outlet to a multi-rail solar-charged battery system. We design power circuits to deliver stable voltages and peak current, manage battery charging by chemistry, and comply with government emissions standards.
Embedded Analog
Every electrical system is analog, digital just hides the details. We bring shielding, emissions control, amplification, filtering, and analog/digital conversion to your design to keep the analog world under control.
Sensor and Instrumentation
Effective instrumentation starts with the right sensor and the electronics needed to convert physical measurements into usable data. Leverage our experience to implement sensor interfaces correctly in your next design.
Controls
Instrumentation relies upon controls to effect changes upon the external world, usually in combination with sensors. We design controls with real-world variability in mind to help you identify and address it effectively.
Communication
Collected data must be transmitted to be useful, whether over wired or wireless connections. Engage with us early to ensure the communication method fits the operating environment and available power.
FAQ
What is PCB design, and what are key manufacturing considerations in the design?
PCB design is the process of creating the schematic and physical board layout for a product’s electronics.
When making design decisions it is important to consider the cost and availability of the components. Also, understanding spacing and line width can impact yield and reliability in production. Consider the manufacturing processes to be used if there are unique requirements for size, finishes, or coatings. A board that has tight tolerances, hard-to-place components, or difficult to source components increase the cost of every unit you build.
What's the difference between schematic design and board layout?
Schematic design defines how components electrically connect. Board layout determines their physical placement and routing on the PCB. Both need to be done with manufacturing in mind, not just electrical function.
What are the differences between production and prototyping PCBs?
Prototype boards can tolerate faster layering with reduced long-term durability and manual component placement. Production boards should be fabricated using processes that increase product reliability, utilize automated assembly processes, and design margins that account for manufacturing variation. Designing for volume from the start avoids a costly redesign later.
What is firmware development, and do I need it alongside hardware design?
Firmware is the embedded software that controls a product’s hardware and is required in nearly all modern electrical designs. Developing hardware and firmware together helps to avoid integration issues and reduces development risk.
How do you reduce PCB manufacturing costs during design?
Cost reduction starts with minimizing PCB layers, avoiding unnecessarily tight tolerances and overly complex components, and selecting readily available parts with multiple sourcing options. Making these decisions during design is far less costly than redesigning a board after production begins.