End-to-end PCB design: schematic, layout, signal integrity, power distribution, thermal management
Multi-layer boards: high-density designs for IoT, wearables, robotics
Wireless integration: BLE, Wi-Fi, cellular antenna design and RF optimization
Power management: battery circuits, low-power design, energy harvesting
Manufacturing expertise: DFM optimization, production testing, supply chain management
50+ shipped products: wearables, industrial sensors, smart devices
OVERVIEW
HARDWARE DESIGN
Custom hardware design transforms product concepts into manufacturable, reliable electronics. This includes
- Component selection and sourcing
Circuit design (analog, digital, power, RF)
PCB layout and manufacturing
Design for manufacturability (DFM)
Production testing and validation
Core Hardware Design Competencies
Circuit Design & Schematic Capture
- We design circuits for microcontrollers, sensors, power management, communication (BLE, Wi-Fi, cellular), and custom analog/digital processing. Component selection optimizes cost, power, size, and availability.
PCB Layout & Signal Integrity
- Multi-layer boards with proper trace routing
Impedance control for high-speed signals
Power distribution networks (PDN) for clean power
EMI/RFI mitigation techniques
Thermal design for heat dissipation
Power Management & Battery Design
Battery-powered devices demand extreme efficiency. We design
- Low-quiescent-current power supplies (microamps when sleeping)
Battery management systems (BMS) for safety
Appropriate battery chemistry selection (Li-ion, Li-po, primary cell)
Energy harvesting circuits (solar, kinetic)
Wireless Connectivity & Antenna Design
Wireless is critical for IoT. We design:
- BLE/Wi-Fi/cellular circuits with matching networks
Antenna designs (patch, monopole, ceramic) optimized for range/efficiency
RF layout for signal integrity
Regulatory compliance (FCC, CE, ISED)
Sensor Integration
We interface diverse sensors
- Accelerometers, gyroscopes, magnetometers for motion
Temperature, humidity sensors for environmental
ECG/PPG sensors for biometric
Pressure, force sensors for mechanical
Optical sensors for vision
Design for Manufacturability (DFM)
We optimize designs for production:
- Component selection (availability, cost, supply chain stability)
Assembly process optimization (pick-and-place, reflow soldering)
Testing strategies (in-circuit testing, functional testing)
Yield improvement (design changes reducing defects)
Thermal Management
High-performance devices generate heat. We design:
- Thermal paths for heat dissipation
Appropriate heatsinks and thermal interface materials
Thermal simulation predicting temperature distribution
Component placement for optimal heat flow
DIFFERENTIATORS
KEY DIFFERENTIATORS
Full-Stack Hardware-Software Integration
Hardware engineers + firmware engineers working together. We optimize hardware for firmware requirements and firmware for hardware capabilities—no “throw it over the wall.
Low-Power Mastery
Battery-powered products are our specialty. We’ve designed systems running on coin-cell batteries for 5+ years—critical for remote sensors and wearables.
Ahmedabad ESDM Advantage
Based in Gujarat’s electronics manufacturing hub, we have deep relationships with PCB manufacturers, contract manufacturers, and component suppliers. This reduces costs and improves timelines.
Real-World Manufacturing Experience
We’ve brought 50+ products from prototype to production. We understand manufacturing bottlenecks, cost drivers, and yield issues—we design accordingly.
Component Sourcing & Supply Chain
Relationships with manufacturers and distributors. We navigate supply chain challenges, obsolescence planning, and cost optimization.
Wireless Expertise
BLE, Wi-Fi, cellular antenna design and RF optimization. We achieve range and efficiency that generic designs miss.
Rapid Prototyping & Iteration
We design for fast iteration: quick boards, testable designs, firmware-friendly interfaces. Fail fast, learn fast.
Overview
Technical Capabilities Deep Dive
PCB Design
- Multi-layer board design (4-8 layers typical)
- High-speed signal integrity: impedance matching, differential pairs
- Power distribution: plane design, via stitching
- Ground planes: low-impedance returns
- Manufacturing tolerances: component placement, trace width, clearances
Wireless & RF
- BLE circuit design: antenna matching, impedance
- Wi-Fi: PCB antenna design, RF shielding
- Cellular (LTE, 5G): modem integration, antenna design
- Regulatory compliance: FCC, CE, ISED testing
Power Management
- Battery selection: chemistry, capacity, discharge curve
- Charging circuits: constant-current/constant-voltage charging
- Battery management systems (BMS): cell balancing, protection
- Low-power design: sleep modes, clock gating, power domains
- Energy harvesting: solar, kinetic, thermoelectric
Sensor Integration
- Accelerometer/gyroscope: vibration, activity recognition
- Temperature/humidity: environmental monitoring
- ECG/PPG: biometric sensing
- Optical: light sensors, proximity detection
- Pressure/force: mechanical sensing
Testing & Validation
- In-circuit testing (ICT): component-level testing
- Functional testing: system-level validation
- Environmental testing: thermal, humidity, vibration
- Electromagnetic testing: EMI/RFI compliance
- Burn-in testing: early failure detection
TECHNOLOGY STACK
PCB Design Tools
- KiCad (open-source, affordable)
- Altium Designer (professional, extensive)
- Cadence Allegro (high-end)
- Component libraries: standardized symbols and footprints
Manufacturing & Fabrication
- PCB manufacturers: PCBway, Eurocircuits, local regional manufacturers
- Contract manufacturers (CMAs): assembly, testing, logistics
- Component distributors: Digi-Key, Mouser, local suppliers
Simulation & Analysis
- SPICE simulation: circuit behavior
- FEA (Finite Element Analysis): thermal and stress analysis
- HFSS: electromagnetic field simulation for RF
- Signal integrity: transmission line analysis
Testing Equipment
- Oscilloscopes: signal measurement and timing
- Multimeters: voltage, current, resistance measurement
- Power analyzers: power consumption measurement
- Logic analyzers: digital signal capture
- Network analyzers: impedance and S-parameters
CAD & Mechanical
- CAD software: SolidWorks, FreeCAD for mechanical design
- 3D printing: rapid prototyping, enclosure design
- Mechanical assembly: ensuring component fit and thermal paths
INDUSTRIES SERVED
Healthcare & Wearables
Applications:ECG/PPG monitors, glucose monitors, activity trackers
Key Requirements:Ultra-low power, medical-grade components, biocompatible materials
Robotics & Drones
Applications:Flight controllers, motor drivers, vision systems
Key Requirements:Real-time performance, power efficiency, compact size
Consumer IoT
Applications:Smart home devices, environmental sensors, wireless controls
Key Requirements:Cost optimization, reliable wireless, battery life
Smart Cities
Applications:Environmental sensors, parking systems, traffic monitoring
Key Requirements:Low cost at scale, long battery life, easy installation
Industrial IoT
Applications:Vibration sensors, temperature monitoring, asset tracking
Key Requirements:Ruggedness, harsh environments, long battery life
Automotive
Applications: Telematics units, ADAS sensors, EV battery management
Key Requirements:Automotive-grade components, thermal management, safety
CASE STUDY EXAMPLES
Akhila Labs supports a wide spectrum of healthcare and wellness applications:
Model 1: End-to-End Hardware Development
Best For: Companies building new hardware products from concept to manufacturing
Includes: Schematic design, PCB layout, prototyping, DFM, production support
Duration: 4–8 months typical
Cost Range: $100K–$300K
Model 2: Custom PCB Design
Best For: Companies with concept, needing detailed PCB design
Includes: Schematic capture, PCB layout, manufacturing coordination
Duration: 4–6 weeks
Cost Range: $20K–$50K
Model 3: Hardware Architecture & Consultation
Best For: Strategic guidance on component selection, power budgets, wireless design
Includes: Technology selection, architecture review, recommendations
Duration: 2–4 weeks
Cost Range: $15K–$40K
Model 4: Manufacturing & Production Support
Best For: Companies with design, needing manufacturing readiness
Includes: DFM optimization, testing strategy, yield improvement
Duration: 6–12 weeks
Cost Range: $30K–$100K
Model 5: Prototyping & Rapid Iteration
Best For: Startups validating hardware concept quickly
Includes: Rapid board design, 3D printing, quick iteration cycles
Duration: 6–8 weeks per iteration
Cost Range: $15K–$40K per cycle
INDUSTRIES SERVED
Frequently Asked Questions
At Akhila Labs, embedded engineering is the foundation of everything we build. We go beyond writing firmware that runs on hardware—we engineer systems that extract
maximum performance, reliability, and efficiency from the silicon itself.
What's the cost of a custom PCB design?
Simple: $10-20K. Medium complexity: $30-50K. Complex with simulation: $75-150K. Includes schematic, layout, manufacturing coordination.
Can we start with off-the-shelf components?
Yes. We often start with eval boards, quickly prototype to validate concept, then design custom board for production.
How many prototype iterations are typical?
2-3 iterations: first for functionality, second for optimization, third for production readiness. Each iteration 2-3 weeks, costs $5-10K.
What's involved in DFM (Design for Manufacturability)?
Analyzing design for production feasibility: component sourcing, assembly process, testing strategy, cost reduction. Takes 2-4 weeks, saves 20-30% manufacturing cost.
How do we ensure wireless performance?
RF simulation, antenna design, proper PCB layout, testing with certified antennas. Takes 2-4 weeks additional. We aim for ±3dBm range variance.
What about battery life optimization?
Energy profiling: measure sleep current, active current, transmission current. Firmware + hardware co-optimization reduces consumption 30-70% typically.
How do we source components if supply chains are tight?
We maintain relationships with distributors, identify alternative components early, design for commonality (use same MCU across products). Helps navigate supply issues.
What's the typical cost per unit in production?
Depends on complexity and volume. Simple: $5-15. Medium: $20-50. Complex: $100-500+. Volume discounts (10x reduction at 100K units).
Can we modify an existing product?
Yes. We reverse-engineer existing boards, improve specific aspects (power, cost, features), redesign for next version. Takes 4-8 weeks.
Case Study 3: Industrial Vibration Sensor – Predictive Maintenance
Challenge A manufacturing equipment company needed vibration sensors for predictive maintenance across industrial facilities. The solution required a rugged design, reliable wireless mesh networking, and battery-powered operation with peak power consumption under 100mA. Solution High-Precision Sensing: 3-axis accelerometer (±16G range) for detailed vibration analysis. Edge AI Processing: STM32L476 MCU running anomaly detection algorithms locally. Mesh […]
Case Study 2: Medical-Grade Wearable ECG Monitor – FDA 510(k) Cleared
Challenge A healthcare startup needed to develop an ECG wearable that met FDA Class II requirements, using medical-grade components and biocompatible materials. The device also required ultra-low power consumption (under 2mA average) while maintaining clinical-grade accuracy. Solution Medical-Grade Components: Selected components meeting AEC-Q200 equivalent standards. Biocompatible Design: Silicone enclosure and electrode materials safe for prolonged […]
Subscribe to the Akhila Labs Newsletter
Get the latest insights on AI, IoT systems, embedded engineering, and product innovation — straight to your inbox.
Join our community to receive updates on new solutions, case studies, and exclusive announcements.