From Idea to Working Hardware in Record Time.
Bridging the chasm between architectural schematics and physical, bench-tested IoT prototypes. Rapid multi-layer PCB spins, hardened RTOS firmware, and seamless cloud connectivity built with DFM rigor from day one.
Dual-Core Cortex-M33 / ESP32-S3 / P4
CORE_LOCKDeterministic Zephyr RTOS • Real-time sensor arbitration
RF Subsystems & Tuned Antennas
50Ω MATCHEDBLE 5.3 Long Range, LoRaWAN 868/915MHz, Cellular NB-IoT
Hardware Cryptographic Trust
SECURE BOOTATECC608A crypto-auth anchor • Encrypted TLS 1.3 OTA
Dual-Core Multimedia AI Smart Frame & Islamic Calendar
Engineering a high-performance single-firmware appliance integrating a 10.1″ MIPI-DSI display pipeline, on-device neural wake word detection, dual-core coprocessing, and real-time cloud voice streaming.
The system requirements mandated zero audio stuttering during simultaneous 1280x800 image decodes, live prayer time calculations with automated Adhan playback, and a real-time full-duplex conversational voice assistant powered by Xiaozhi and local WakeNet models.
Drives 10.1″ MIPI-DSI, JPEG chunking, audio mixing, and neural voice detection.
High-speed 4-bit SDIO transport (CLK 18, CMD 19, D0-D3) offloading network stacks.
| Subsystem | Silicon / Controller | Bus & Pin Configuration |
|---|---|---|
| Display | 10.1″ IPS (1280x800) | MIPI-DSI • Reset 27, Backlight 23 |
| Touch Panel | GSL3680 Capacitive | I2C (SDA 7, SCL 8, INT 21, RST 22) |
| Audio Codec | Everest ES8311 + PA | I2C 0x18 • I2S: MCLK 13, BCLK 12, LRC 10, DOUT 9, DIN 11 |
| Storage | TF MicroSD Slot (FAT32) | 4-Bit SDMMC Slot 0 (GPIO 39-44) • On-chip LDO CH4 |
| Hardware RTC | Epson RX8025T + CR1220 | I2C 0x32 • Offline prayer & clock failover |
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Non-Blocking PSRAM Double-Buffering: Reads large photos in 256KB chunks, releasing the SD card bus between chunks so the audio task feeds playback buffers without starvation.
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Local Neural WakeNet ("Jarvis"): Embedded 290KB ESP-SR model running in a background task; zero microphone audio streams to the cloud until wake-word activation.
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Full-Duplex Opus Streaming: Microphone data captured at 48kHz, downsampled to 16kHz, Opus-encoded in 60ms frames, and piped over WebSockets to Xiaozhi.
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Dual-Slot Fail-Safe OTA: 16MB flash mapped with active (app0) and backup (app1) slots, allowing browser-based remote updates with rollback protection.
Unified 5.8MB PlatformIO Image
All drivers, MIPI-DSI graphics, multi-touch tracking, SDIO networking, audio decoders, and voice assistants run reliably from a single production-ready binary.
Meet the Founder & Lead Systems Architect
No account executives, no junior delegation. Your hardware is scoped, routed, and bench-tested directly by an experienced engineer.
Hardware prototypes shouldn't be trapped in bureaucratic development cycles or multi-month agency backlogs. At ProtoForge, I partner directly with founders, R&D teams, and hardware pioneers to compress early-stage development from quarters into weeks.
My approach combines rigorous embedded firmware design with high-speed PCB layouts and end-to-end IoT connectivity. Every design is built with Design for Manufacturability (DFM) from day one—ensuring your proof-of-concept doesn't require a total redesign when transitioning to volume manufacturing.
You communicate directly with the person routing your traces and testing your firmware on the oscilloscope.
You retain 100% unencumbered rights to native CAD files, firmware Git repos, and manufacturing BOMs.
Interactive Prototype Estimator
Select your target technical specifications to compute real-time sprint timeline and ballpark budget forecasts.
Strictly confidential • No obligation review
Engineered for Reliability at Scale
From raw schematic design to production firmware and DFM compliance.
Custom PCB Design
Schematic capture, high-speed routing, controlled impedance, RF strip-lines, and fast-turn in-house SMD pick-and-place assembly.
- • Altium / KiCad native files
- • Impedance & RF matching
- • DFM-scrubbed active BOM
Firmware & RTOS
Production-conscious C/C++ firmware built on Zephyr RTOS or FreeRTOS to eliminate rewrites when transitioning to volume.
- • Sub-1.5μA deep sleep profiles
- • Peripheral SPI/I2C/CAN drivers
- • Encrypted bootloaders & OTA
Wireless & IoT Pipes
Reliable RF communication designed to perform in challenging environments with zero dropped packets.
- • BLE 5.3 Long Range / Mesh
- • Cellular NB-IoT & LTE-M
- • AWS IoT Core MQTT streaming
Mechanical Enclosures
Protecting your electronics with precision 3D CAD design, functional snap-fit SLA/FDM cases, and gasket sealing.
- • STEP 3D CAD models
- • Connector & antenna clearances
- • IP-rated splash testing
Hardware Lab & Proven Platforms
Ultra-Low-Power Telemetry Node
Dual-core ARM Cortex-M33 asset tracker featuring integrated BLE 5.3 Long Range, GPS fix engine, and dynamic battery management.
Industrial Edge Controller
480MHz Cortex-M7 controller engineered for rugged environments with dual galvanically-isolated CAN-FD, RS-485, and redundant power rails.
Smart Edge AI Sensor Hub
Vector neural-network accelerated dual-core MCU performing on-device acoustic vibration classification and live AWS IoT Core sync.
How We Deliver Prototypes in Weeks
A battle-tested milestone methodology eliminating surprises, scope drift, and rework.
Architecture & BOM Lock
Pinout allocation, component supply-chain validation, and hardware/software boundary freeze.
CAD & Schematic Routing
High-speed layout routing, RF matching calculations, and simultaneous 3D enclosure modeling.
Board Spin & Assembly
PCB fabrication, in-house SMT assembly, bench bring-up, and baseline firmware flashing.
Validation & IP Handoff
Oscilloscope signal characterization, functional units dispatch, and complete Git/CAD ownership transfer.
100% Client Intellectual Property Guarantee
UNRESTRICTED OWNERSHIP • MUTUAL CONFIDENTIALITY
We operate as your dedicated engineering arm, not an agency retaining proprietary IP. You retain full and unencumbered legal ownership of all outputs generated during our sprints: