Reverse Engineering Projects

PCB Hardware Reverse Engineering Projects

We have vast experience in the field of electronic hardware reverse engineering. If we haven’t made your exact product before then we’ve probably made something similar. Our reverse engineering laboratory is not only able to make your electronic circuit board replacement as a clone, copy or upgrade (assuming the PCB is unsupported by the OEM) we can also reproduce your hardware using our state of the art 3D printer.

See below for just some of the products we have reverse engineered, see the see our ENA’s 8 Step Electronic Hardware PCB Clone, Copy + Upgrade Process to see how we did it.

central processing unit for reverse engineering project — Central Processing Unit: 8 Layers, Leght of traces 62922mm, Number of holes 2002, Vias 1064, Twin Central Processing Unit – two complete CPU systems on a single-slot VME BUS module, VME BUS interface, slave interface, controller extension connector.

high voltage control unit press — High Voltage Control Unit Press: This project was a reverse engineering project for an obsolete product. For this project we reverse engineered both the current transformer and the power transformer and sourced hard to find / obsolete parts.

control logic board a — Control Logic Board A: This project was interesting for us as the customer asked us to take a military grade PCB and make it out of regular off the shelf parts. Included in this reverse engineering project was making our own custom potted modules and finding replacement ICs.

control logic board b — Control Logic Board B: Part of the same project as Control Logic A we took the military grade PCB and made an industrial version. With our huge supply network we were able to source hard to find parts and clone the board ready for our customer.

ge fanuc hmi replacement keypad — GE Fanuc HMI Replacement Keypad: A million dollar machine was down because the go button stopped working. We got a hold of the keypad, worked out the pinout and developed a replacement keypad. The customer installed the keypad and with one press they were back up and running.

fanuc/fujitsu a98l0010621/02 replacement keypad — Fanuc / Fujitsu A98l0010621/02 Replacement Keypad: We made this replacement keypad as the original keypad was worn and broken, the customer had no options left with nothing on the market. We took the original design, designed the files and manufactured a replacement which the customer was able to use right away.

quickpanel hmi replacement overlay for reverse engineering project — Quickpanel HMI Replacement Overlay: The customer had a damaged HMI overlay. The replacements were unavailable so we made a replacement, this allowed the customer many more years of use on the HMI.

power supply protection board — Power Supply Protection Board

analog output protection — Analog Output Protection

cnc stepper motor drive control board — CNC Stepper Motor Drive Control Board

allen bradley series 9 keypad replacement — Allen Bradley Series 9 Keypad Replacement: In this reverse engineering project we upgraded an original Allen Bradley Series 9 HMI’s keypad with a cloned + upgraded tactile switch equivalent. This retrofit allows future repair much needed in demanding environments.

analog to digital card — Analog to Digital Card: This card was a 4 layer PCB communicating through a backplane to a controller running on VMEBus. Once we built the card we made a full function test rig.

backplane replacement — Backplane Replacement: This backplane even came in with burnt components, we reverse engineered the schematic from the PCB + cloned the board, upgrading parts for modern equivalents.

contactor driver for reverse engineering project — Contactor Driver: Our customer came to us asking if we could reverse engineer a board they were having trouble with. We not only cloned it but we built a test rig + helped with the commissioning.

analog control card — Analog Control Card: This control card clone allowed the customer to drop in a replacement for their obsolete machine, saving them thousands on a new machine + giving them spares for the future.

Control Relay Card: After sourcing the hard-to-find components for this industrial control relay card we sent it to the customer. Needless to say it worked the first time.

custom rs232 pcb — Custom RS232 PCB: This device was a brand new design for us. The device connected via RS232 to a VFD drive + by using our custom firmware they could control their drives.

digital interface card — Digital Interface Card: Particular attention to detail was required on this project as the customer required over 30 units + they were for a nuclear power plant – they had to work the first time.

handheld keypad for reverse engineering project — Handheld Keypad: The customer came to us with an old, non-working controller + asked for a replacement. We designed + manufactured this unit from the ground up.

hybrid smd pcb — Hybrid SMD PCB: Not only can we reverse engineer PCBs with through hole components but we have facilities to populate + solder SMD’s (Surface Mount Device) too.

interface board for reverse engineering project — Interface Board: A large multi-national company came to us with this reverse engineering project. They needed their bandboard circuit made into a modern PCB. This is what we came up with.

smps power supply — SMPS Power Supply: This switched mode power supply needed to be an exact fit-form-function replica for the customer. We even custom made the switching transformer!

upgraded pcb — Upgraded PCB: The customer gave us the original board + asked for some feature upgrades on the old board. We added power + function LED’s + connectors.

op amp card — OP AMP Card: This PCB required extremely high precision resistors + components that were obsolete. We not only sourced them but supplied 50 units to our customer.

power supply card — Power Supply Card: The DC-DC power supply on this card was completely unavailable. We sourced a replacement, upgraded the board + provided documentation.

burny overlay — Burny Overlay: Burny 1400 Llus Replacement Keypad

custom made data logger — Custom Made Data Logger: Original, Version 1, Version 2, Version 3

digital input board — Digital Input Board: 24 opto-isolated digital inputs for up to 60VDC

digital output card — Digital Output Card: 16 opto-isolated 24 VDC outputs.Smart transistor outputs

emergency light inverter replacement board — Emergency Light Inverter Replacement Board

IO board — IO Board: Customer Email “I have a need for reverse engineering of multiple circuit boards that we have for a machine type in which we have 24. There are probably at least 10 boards per machine. The boards are over 20 years old and have been repaired too many times. We have some electrical drawings that we can provide. Please let me know what you need in order to quote building these for us so that I can get all of the pertinent information together for you.”

replacement for limit switch part — Replacement for Limit Switch Part: (Wind turbine) 3D Design and Fabrication

temperature transmiter — Temperature Transmiter: RTD 200 input output 4-20 mA Tolerance 0.1%

UV light controller — UV Light Controller

status board for reverse engineering project — Status Board: RS232 communication, two 8K by 8 EPROMS, WD relay, LEDs, 15 pin DSUB

OPAMP + static switch — OPAMP + Static Switch: Replacement Board for ML4006L3315G001

snubber board — Snubber Board: Replacement for obsoleted Snubber Board

customer made power supply — Customer Made Power Supply

Legacy Product Re-manufacturing

Reverse Engineering Project: Value Added Services

Reverse engineering includes more than just cloning and upgrading. The process of creating or recreating a full assembly can also include manufacturing covers, casings, or overlays in addition to incorporating batteries into the assembly.

3D printing

Metal is not always the most conducive medium for all builds. Some things need to be light and ergonomic, yet durable. Both engineering projects and repairs can involve replacing plastic casings but for a custom design and when two dimensions just aren’t enough, 3D printing is the best option. Our 3D printer has a large print volume enabling prints up to 400mm x 400mm x 700mm. Get in touch with your project requirements for a quote.

Vinyl + Lexan Overlays

Much like how a common HMI can have its overlay replaced as part of its repair, so too can a custom overlay be manufactured as part of an engineering project.

Battery Spot Welding

Some assembly is required, but batteries are always included. Using a battery spot welder we can make our own battery packs and battery assemblies for any engineering + repair project. We can produce any battery that you need for backup or your custom reverse engineering project.