As an experienced freelance electronic design engineer, I offer specialized reverse engineering services tailored to the needs of small manufacturers. Many of these manufacturers have been making the same products for decades and may no longer an in-house engineer. They often seek my expertise when their contract manufacturer is unable to assist with modifications to a PCB or electronic assembly.

The products I typically work on are often over ten years old, featuring outdated technology such as through-hole components and unidentifiable chips with markings in foreign languages or deliberately obscured. In many cases, when I request schematics, I find that they are unavailable. The original designer might no longer be in business, or the documentation may have been lost. At best, I might receive a Gerber file and a bill of materials (BOM), but sometimes even these are missing.

When it comes to software changes, the scenario is often similar. Requests for the source code usually result in a negative response. If I am provided with a board and permission to destructively analyze it, I may attempt to extract the hex file from the chip. However, protection bits are frequently set, rendering this impossible. In such cases, I analyze the board’s functionality and develop a specification, which is then agreed upon with the customer. This step is crucial, as customers often only realize their specific needs once they see a prototype.

For straightforward circuit changes, such as adding a resistor or modifying a component footprint, extensive reverse engineering may not be necessary. I can make these adjustments by editing the Gerber files. However, more complex tasks typically require the creation of a new PCB. This process involves recreating the schematic diagram from the Gerber files and BOM or through direct inspection, followed by designing a new PCB from scratch. In cases where software is involved and the source code is unavailable, I redesign using modern components and write new code. This method is generally more efficient and cost-effective than attempting to work with obsolete technology, often resulting in a less expensive final product, much to the satisfaction of the customer.

Upon completion of the project, I provide the customer with all the CAD files and source code in a ZIP file on a CD or flash drive, recommending secure storage for future reference. However, I am aware that this advice is not always heeded.

My reverse engineering services include:

• Detailed analysis of outdated PCBs and electronic assemblies
• Recreation of schematic diagrams from Gerber files, BOMs, or direct inspection
• Modification of existing PCB designs
• Development of new PCBs based on existing designs
• Extraction and rewriting of firmware using modern components
• Comprehensive documentation of the design process for future reference

Through my expertise in reverse engineering, I ensure that your products can be effectively updated and maintained, extending their lifecycle and enhancing their performance.

Ready to bring your electronic design project to life?

Contact me today to discuss your requirements and see how my expertise can help you achieve innovative, high-quality, and reliable solutions. Whether you need circuit board design, electronic prototyping, or custom firmware development, I am here to provide the services and support you need. Let’s work together to turn your vision into reality. Get in touch now to start your project!