We design hardware the way we design software — modular, testable, and built to evolve. Software-oriented design means upgrades without changing hardware.
The Approach
Most hardware companies start with the circuit and figure out the software later. We do the opposite. We define the algorithms, data flows, and connectivity requirements first — then select the simplest, lowest-cost components that satisfy them.
This software-oriented approach means the hardware is designed for upgradability. When algorithms improve or new features are needed, the firmware updates — the board stays the same.
The result: lower BOM costs, faster iterations, and products that get better over time without hardware revisions.
Because we understand both the electronics and the firmware at a deep level, we can confidently micromanage low-cost overseas circuit design, packaging, and manufacturing — getting the quality of an expensive local engineering firm at a fraction of the price. You don't need a large hardware team. You need one expert who knows exactly what to specify and how to verify it.
The Process
A proven pipeline that minimizes risk and maximizes cost efficiency at every stage.
Define algorithms and data flows. Select components. Develop and test C/C++ code in a simulated environment — before any hardware is built.
Build Arduino prototypes to test critical hardware dependencies — sensors, actuators, connectivity. Validate real-world performance against simulation.
Contract PCB design, manufacture via JLCPCB, integrate production firmware on Microchip/ST Micro, and package with our Shenzhen partner. Ready to ship.
The Stack
From microcontroller to mobile app — everything under one roof.
Microchip PIC and ST Microelectronics STM32 families. Selected for cost, availability, and driver ecosystem. Production-grade with full library support.
Bluetooth Low Energy, Wi-Fi, USB, and serial protocols. Chosen per application — BLE for wearables, Wi-Fi for stationary devices, USB for data-heavy transfers.
Accelerometers, gyroscopes, magnetometers, pressure sensors, IMUs. Low-cost, proven components selected for reliability and ease of integration.
C/C++ developed in simulation, prototyped on Arduino, deployed to production silicon. Modular architecture designed for OTA updates without hardware changes.
PCB fabrication and assembly via JLCPCB. Enclosures, batteries, and packaging designed and produced with our manufacturing partner in Shenzhen.
Flutter mobile apps with Firebase backends. The device captures data, the app displays it, and the cloud aggregates it — a complete product ecosystem.
Case Study
A gait rehabilitation wearable built from concept to manufacturing using this exact process.
The Heel2Toe device helps Parkinson's disease patients improve walking patterns through real-time biofeedback. It includes a custom PCB with IMU sensors, BLE connectivity, embedded C firmware, and a Flutter companion app.
The hardware was designed for simplicity: a single microcontroller, one IMU, BLE radio, and a rechargeable battery. The intelligence lives in the firmware algorithms — signal processing, gait detection, and real-time feedback — which have been updated multiple times without any hardware changes.
PCBs manufactured by JLCPCB, enclosure and packaging from Shenzhen, companion app on iOS and Android.
From concept sketch to manufactured product — let's talk about what you need built.
ted@appliedrd.com