How We Built 10 Reliable Electronic Devices for Harsh Marine Environments

Developing electronics for marine applications requires a precise combination of technical expertise, rigorous process discipline, and deep understanding of harsh operating conditions.

These systems must operate reliably at temperatures exceeding 70°C , withstand continuous vibration levels above 4 g, and comply with strict marine regulatory standards such as IACS UR E10 and DNVGL-CG-0339,  while their footprint must be reduced by 75% to enable integration in narrow machinery spaces.

They must be built with simple, lean functionality, using widely available, vendor-independent components to ensure reliable operation and long-term availability over 10–15 years.

Project Background

Our client had secured a large-scale project for their end customer – the development of electronics for marine applications – but faced a critical capacity gap. With milestones approaching and the workload split between our team at ARS and their existing partner, the first development phase exposed serious risks: schedule delays and inconsistent prototype quality. The client recognized our tight development cycles, structured documentation practices, and rigorous prototype validation, and decided to reassign full development responsibility to ARS.

Here is how we managed a technically complex multi-device project under challenging logistics and time constraints – showing how careful component selection, rapid prototyping, and end-to-end verification enabled us to deliver a compact, robust system ready for marine certification.

Key Challenges and Project Complexity

  • Ten distinct PCB designs, each with unique electrical and mechanical requirements.
  • Reducing the system size and footprint by 75% compared to existing state-of-the-art systems.
  • Securing critical ICs with lead times, requiring alternative sourcing strategies.
  • Implementing robust surge and reverse-polarity protection for sensitive inputs and modules.
  • Synchronizing communication between multiple controllers to form a unified management system.
  • Managing complex logistics and coordinating builds across multiple EMS vendors under tight deadlines.
  • Reducing first-prototype to identify and fix issues early.

Our Approach

Analysis of existing system and requirements:

  • Reviewed client specifications and marine-specific technical requirements.
  • Flagged conflicting and incomplete requirements.
  • Analyzed technical risks and created mitigation strategies.
  • Flagged high-risk components with excessive lead times and prepared alternative BOM options.

Concept development:

  • Adapted existing designs that used hard-to-source chips to versions based on standard controllers available from multiple vendors.
  • Developed quick PoC boards to verify conceptual design.
  • Performed environmental tests on PoC boards to verify reliability and detect early risks.

Detailed design and prototype development:

  • Created detailed electrical schematics and ran early signal-integrity simulations to avoid layout rework.
  • Designed PCBs and prepared manufacturing files, selecting board houses with proven marine experience.
  • Organized production of the first prototype batch with parallel firmware bring-up to compress schedule.

Firmware preparation and testing:

  • Developed and tested firmware for the first prototypes.
  • Performed essential verification tests to confirm power and basic I/O integrity before full functional testing.
  • Conducted detailed verification testing covering thermal cycling and random vibration screening.

Outcomes

  • Delivered a compact, reliable system on schedule
  • Reduced board size while meeting all marine environmental and EMC requirements
  • Minimized risks in supply chain disruptions through multi-vendor component strategies.
  • Increased robustness by resolving communication and thermal issues early in prototyping.
  • Helped the client hit critical milestones and maintain confidence with their end-customer.
  • Additionally, the client was satisfied already during our development work and directly ordered the development of system extensions with additional interface boards.

Key Factors That Ensured Project Success

  • Thorough review of requirements and upfront preparation
  • Development of multiple conceptual solutions, supported by simulations and initial PoC testing
  • Transitioning from hard-to-source chips to standard components reduced procurement risk
  • Fast decision-making on component substitutions and PCB changes kept prototypes on track.
  • Comprehensive testing at every stage caught issues before they reached production.
  • Consistent focus on clear documentation and disciplined change control prevented rework.
  • Close coordination with EMS vendors ensured parts availability and aligned build schedules.

Conclusion

The project’s success came from a blend of the right capacity and proven expertise.
Our team combined the necessary engineering capacity with deep experience in designing systems for harsh environments, drawing on prior work in industrial automation to handle heat, vibration, and electrical noise.Supported by structured processes, transparent communication, full traceability from concept to validation, and excellent client support, we delivered a rugged solution on schedule and ready for the field.

If you’re facing similar challenges, let’s explore how we could support your next project.