PCB redesign after an EOL notice — drop‑in replacement in 6 weeks.
PCB redesign & EOL management
Hardware RE · KiCad · firmware migration · small series production
Baseline
The motor driver IC on the main control PCB of a packaging machine was discontinued (EOL). Last stock was gone; grey-market prices: €4,800 per board. Three boards in operation, one as spare. A new packaging machine: €280,000 + 4 months lead time.
Approach
PCB reverse engineering
Full schematic extraction. All components identified. EOL IC electrically characterized (inputs, PWM, timing) using an oscilloscope during operation.
Replacement component & design
Found a modern motor driver IC (same function, 10‑year availability commitment). Re-drew PCB layout (same form factor for drop‑in). Improved thermal design.
Firmware & testing
Integrated register configuration for the new IC into existing firmware (no business-logic change). SOA load test. 500‑hour run test without faults.
Small series production
Produced initial batch of 10 boards. Created pick‑and‑place program. Delivered full quality control documentation.
Cost savings
Cost savings
Direct comparison
New purchase (replacement)
€ 280.000
Solvetronix
€ 38.000
You save
€ 242.000
Savings
86 %
Typical ROI: immediate
Additional benefits
Technologies
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