Firmware Development Services for Physical Products

We help hardware teams avoid unstable device behavior, integration issues, and costly debugging by developing firmware around the real electronics, mechanics, and product logic from the start. EnCata is an IoT development company providing firmware architecture, device logic, programming, integration, testing, and documentation for connected hardware products.

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TRL 3-8 Lifecycle
Bare Metal, RTOS, Embedded Linux
From consumer devices to industrial systems
Expert Insight

What’s Included In Firmware Development

We develop firmware as the control layer of your hardware product.

It defines how the device starts, senses, calculates, communicates, reacts to errors, and stays reliable in real use.

Firmware architecture

We define operating modes, module structure, data flow, timing logic, and interfaces before implementation starts.

Low-level programming

We write drivers, control logic, algorithms, state machines, and communication layers for MCUs, processors, PLCs, or FPGA-based systems.

Hardware bring-up & debugging

We launch firmware on real boards, test peripherals, debug sensors, actuators, displays, power systems, and communication modules

Integration-ready delivery

We prepare tested builds, documentation, deployment logic, and interfaces for cloud, mobile apps, production tools, or further development.

Meet EnCata Team

We serve as your dedicated engineering team, eliminating the hassle of coordinating with various freelancers or companies.

45+
team
12
Ph.D.
10
electronics and firmware engineers

Want to Develop a Custom Solution?

Our team is eager to discuss how we can assist you and answer any questions you may have. Don't hesitate to reach out!

Book a call

Why EnCata

Competitive prices

Our rates are significantly lower than those of a typical US firm.

Work globally, ship globally

No matter where your team is based, we can deliver prototypes, firmware builds, test samples, and documentation without logistical hassle.

Integrated hardware, firmware, and production team

We work as one team under one roof across hardware, firmware, prototyping, and production, aligning decisions early so the product develops as a cohesive system.

Your IP stays yours

NDA by default. Full IP transfer.

Enclosure Design PRIORITIES

Firmware Development Technology Stack

For 15 years, we have been refining our internal processes and expanding our technology stack to tackle more complex embedded systems. The list below is not exhaustive, and you can always specify what you need for your project in the contact form.

MCU, MPU & programmable logic

STM32
NXP
Nordic
Texas Instruments
ESP32
GD
JL
MCU
MPU
FPGA
CPLD
PLC
DSP

Firmware architecture & operating systems

Bare Metal
Superloop
RTOS
FreeRTOS
Embedded Linux
ROS
ROS2
Bootloaders
Low-level drivers
Third-party software stacks

Programming languages

C
C++
C#
Python
ASM
VHDL
Verilog

Connectivity & communication

Wi-Fi
BLE
Bluetooth
LoRa
LoRaWAN
NB-IoT
NFC
GPS
GPRS
3G / 4G
SubGHz
UWB
MQTT
Modbus
Ethernet

Interfaces & buses

USB
SPI
I2C
UART
RS-232
RS-485
I2S
CAN
LVDS
CSI
DSI
SD / SDHC / MMC
1-Wire

Testing, debugging & integration

Board bring-up
Firmware debugging
Code refactoring
Unit testing
Deployment
Firmware upload
Protocol development
Interface integration
Industries

We Design Across Various Industries

Deep domain understanding increases the success rate of your product.

Consumer & Wearables
IIoT & Automation
Industrial Equipment & Tools
Analytical & Lab Equipment
Agriculture
Green Tech
Healthcare
Robotics
Smart City
Food Tech
Vehicles
Other
Consumer & wearable

Consumer & wearable

96
projects delivered

Our team specializes in full-cycle consumer electronics and wearables development and manufacturing. Explore the page to see relevant project examples.

See how we deliver
IIoT & automation

Industrial IoT (IIoT) and Automation Hardware Solutions

15
projects delivered

EnCata will automate your production facility or warehouse with sensors, actuators, and edge computing, providing real-time data processing and efficiency.

See how we deliver
Industrial equipment & tools

Custom Industrial Equipment & Tools

243
projects delivered

Can’t find the right equipment? Discover how EnCata’s custom-built solutions tackle your unique challenges and enhance your production efficiency.

See how we deliver
Analytical & lab equipment

New Analytical & Laboratory Equipment Development

12
projects delivered

Explore EnCata’s custom solutions for analytical and lab equipment. Discover our precision design and development services—click to enhance your lab today!

See how we deliver
Agriculture

Custom Agricultural Hardware Solutions

8
projects delivered

EnCata helps bring your new tech in agriculture to life, including precision agriculture and robotic farming, turning your innovative ideas into reality.

See how we deliver
Green tech

Green Tech

projects delivered

This page is still under development. If you're interested in our experience in this field, please fill out the contact form and we’ll get back to you.

See how we deliver
Healthcare

Healthcare

23
projects delivered

Expertly developed, tested, and manufactured devices ready for market entry. We guide your product through all stages to market. Go test our expertise!

See how we deliver
Robotics

Robotics Solutions for Cutting-Edge Automation

6
projects delivered

Custom robotics solutions for automation—robotic arms, AGVs, and more. Contact us to develop tailored robotics systems for your business needs.

See how we deliver
Smart city

Smart City

projects delivered

This page is still under development. If you're interested in our experience in this field, please fill out the contact form and we’ll get back to you.

See how we deliver
Food tech

Custom Hardware Solutions for Food and Drinks

6
projects delivered

We develop custom solutions for food and drinks: from dosing and filling systems to quality control, and automated cooking systems. Contact us today!

See how we deliver
Vehicles

Vehicles

projects delivered

This page is still under development. If you're interested in our experience in this field, please fill out the contact form and we’ll get back to you.

See how we deliver
Other

Other

projects delivered

This page is still under development. If you're interested in our experience in this field, please fill out the contact form and we’ll get back to you.

See how we deliver
Expert Insight

Firmware Is Not Abstract Software

Firmware is written for a specific physical device. It must understand how the electronic circuit works, how signals behave, how sensors produce data, how actuators respond, and where mechanics can limit the final behavior.

That is why firmware development cannot be isolated from hardware engineering. A command in code may look simple, but in a real product it depends on voltage levels, timing, noise, connector layout, motor inertia, enclosure geometry, heat, battery behavior, and user interaction.

Schematic-aware development

Firmware depends on pinout, power domains, buses, pull-ups, interrupts, ADC behavior, and peripheral limits.

Mechanics affect logic

Motors, pumps, valves, buttons, airflow, enclosure fit, and user handling can change how firmware should control the device.

Edge-case behavior

Startup, shutdown, retries, fault states, watchdogs, recovery, and safe modes define whether the product feels reliable.

Expert Insight

Featured projects

Work that highlights the incredible technologies, solutions, and products EnCata developed

View all portfolio
IIoT & automation

Custom IIoT Solution for Thermal and Water Flow Control

IIoT solution combining thermal metering, flow regulation, and smart valve control. Built from scratch (TRL 1) and deployed in real infrastructure (TRL 9). All IP belongs to the customer.

9.5%

reduction in heat energy after installing the custom IIoT system

280%

reduction in CAPEX reduction from replacing legacy heat metering infrastructure

View Project
Consumer & wearable

Custom IoT 5-in-1 Air Purifier

EnCata developed a multifunctional IoT device that purifies, humidifies, ionizes, and monitors indoor air. We supported a consumer startup as an engineering contractor — from concept and embedded software to pilot production. All IP belongs to the customer.

2

successful crowdfunding campaigns

5-in-1

features delivered in one device, replacing multiple single-purpose products

View Project
Analytical & lab equipment

Heat Chamber Control Cabinet

EnCata developed a control cabinet that manages a heat chamber (60 °C heating, humidity, ventilation, safety) and integrates a cold chamber and chiller via RS-485 for one of its customers. The cabinet is part of a climate system designed for simulating extreme temperatures for firefighters.

6 kW

total power of the heating circuit

60 °C

upper temperature limit 

View Project
Agriculture

Smart Soil Irrigation System Development

EnCata helped a startup develop a smart soil irrigation system from concept to MVP. The system includes custom electronics, BLE, LoRaWAN, and solar-powered modules for real-time soil monitoring and control. Built and tested in just 8 months.

5 kms

range of operation

2 control options

remotely through the mobile network and directly via Wi-Fi modules

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Vehicles

Electric skateboard for urban mobility

We helped an electric mobility startup turn a raw prototype into a smart, IoT-connected skateboard for city commuting. The device is a reliable, eco-friendly, convenient, and intelligent type of urban transport with the possibility of integration into urban infrastructure.

3 patents

filed as a result of our R&D efforts

7.0 kg

final weight (2–3× lighter than typical alternatives)

View Project
Smart city

Self-managed cold electronic storage for digital assets custody

EnCata developed a custom electronic storage vault for a fintech customer, integrating over 8,194 Spark™ wallets. The vault enables secure storage and blockchain-controlled transactions. We delivered enclosure design, DFM, and a functional prototype.

600 kg

steel prototype with bulletproof glass

8,194

Spark™ hardware wallets incorporated

View Project
Consumer & wearable

8K VR Headset for Sports

EnCata developed an 8K VR headset for sports training which featured ultra-high resolution, a wide field of view, and compact dimensions. It allowed real-time interaction between players in different places. The prototype was ready for pilot production in just 8 months.

8K

display resolution

90-110°

field of view

View Project
0
0

Want to develop a custom solution?

Our team is eager to discuss how we can assist you and answer any questions you may have. Don't hesitate to reach out!

Discuss your project
PRODUCT MATURITY

Electronics Maturity Stages

From electrical architecture to pilot-ready hardware. Each stage answers a different product-readiness question.

Proof of concept device

Is the selected electronic architecture viable?

1 – 2 weeks
Product State
Development boards, evaluation kits, breadboard setup, early schematic, or rapid PCB prototype
System Behavior
Core sensing, control, power, or communication principle is demonstrated
Engineering Focus
Component selection, power rails, sensor approach, communication interfaces, architecture risks
trl
4

Functional PCB prototype

Does the system work on custom hardware?

2 – 4 weeks
Product State
Custom PCB or assembled engineering PCBA with key components and interfaces
System Behavior
Main circuits power up, peripherals respond, and core operating modes work on the actual board
Engineering Focus
Schematic design, PCB layout, board bring-up, signal behavior, power stability, peripheral testing
trl
5

Engineering validation unit

Does the electronics remain stable as part of the product?

2 – 4 weeks
Product State
Assembled engineering prototype with electronics integrated into mechanics, enclosure, firmware, and interfaces
System Behavior
The device performs full workflows under controlled but realistic operating conditions
Engineering Focus
Integration testing, thermal behavior, EMI risks, DFM/DFT updates, BOM refinement, debug reports
trl
6

Pilot-ready device

Can the electronics move toward pilot production?

2 – 4 weeks
Product State
Pilot-ready PCB revision with production files, BOM, firmware flashing logic, and test procedures
System Behavior
Repeated samples can be assembled, powered, tested, and debugged through a defined workflow
Engineering Focus
Manufacturing readiness, production test, documentation, supplier transfer, QA workflow
trl
7

Our Approach to Electronics Development

Through dozens of electronics projects, we’ve learned that a reliable board starts with well-defined requirements that shape the system architecture and every subsystem decision.

The list below is not exhaustive, but highlights what matters most.

Requirements translated into circuits

We turn product requirements into power, sensing, control, connectivity, protection, UI, and test blocks (every circuit has a clear product reason behind it).

Subsystems designed as one device

PCB, firmware, enclosure, sensors, batteries, and communication modules are mapped together to avoid integration issues after the board is already routed.

Risky nodes tested first

Power rails, RF paths, analog signals, high-current circuits, and critical interfaces get extra attention because they are the most expensive to fix after PCB manufacturing.

Production files for real manufacturing

BOM, Gerbers, drilling files, assembly data, DFM/DFT notes, and component alternatives are prepared around manufacturer constraints, so the board can be built repeatedly.

Comprehensive Service Scope

Related engineering services that support electronics development and help turn a working PCBA into a complete hardware product.

Firmware development

Embedded software, drivers, control logic, connectivity, and board bring-up support that make the electronics perform as intended in the final device.

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Mechanical engineering

Enclosures, internal layout, connector access, cable routing, cooling paths, sensor placement, and assembly constraints that shape how the electronics fit and operate.

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Computer simulations

Thermal, airflow, vibration, stress, signal, and power-related analysis to identify risks before the first batch.

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Rapid prototyping

Physical prototypes, test fixtures, enclosure samples, assembled units, and iteration support for testing electronics in real product conditions.

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FAQs

Frequently Asked Questions

Have a question that needs a human to answer? No problem.

Speak to our Sales Team now
What does electronics development include?
Do you develop custom PCBs from scratch?
What types of PCBs can EnCata design?
Can EnCata improve an existing PCB design?
Can you develop power electronics and battery systems?
Do you develop firmware too?
Do you perform simulations for electronics?
Can you support PCB manufacturing?
How long does an electronics development project take?
Do you sign NDAs?
Who owns the IP?

services

Hardware DevelopmentElectronics DevelopmentFirmware DevelopmentMechanical EngineeringComputer SimulationsIndustrial DesignDesign for ManufacturingRapid PrototypingFeasibility StudiesLow Volume Manufacturing

About encata

Our StoryOur PartnersNews & EventsPartnership Opportunities

Resources

PortfolioBlogFor SMEsFor StartupsProcessesFAQ
ENCATA LOGO
EnCata 2008 - 2026 © All rights reserved /
Privacy Policy
EnCata, Ltd

Firmware development services

One of the core EnCata's competencies is firmware and embedded software systems development. We assist startups, SME, enterprise-level businesses in the development of low-level software.

Talk to an Expert

Embedded software outsourcing

Practically no modern smart device is able to function without firmware. EnCata works at all stages of a new product development, and provides embedded software development services for such industries as Consumer & Wearables devices, AgriTech & Smart Farming, Сlean Tech, Robotics and Healthcare.

Based on our experience, you will shorten your project by 2-5 months if you develop hardware and firmware within the same team. The best outcomes are obtained when firmware programming and hardware development are handled by the same group of specialists.

Our team includes not only Embedded Firmware Development specialists, but also Electronics Developers and PCB Designers. We work with the most demanded technologies - from Bare metal to Linux Embedded.

Embedded software architecture development:

• Algorithmic processing on the MCU;
• Digital processing of the DSP signals;
• Development of interfaces for communication with PCs and other devices.

Firmware optimization. Design review:

• Refinement of the software source code for the customer's needs;
• Refactoring the code of the existing firmware.

Programming processors and microcontrollers:

• FPGA;
• CPLD;
• PLC.

Embedded software development: 

• For devices without an operating system (Bare Metal)

Integrated Development Environment:

• Development without OS (Superloop);
• Development with the use of RTOS
• Development with the use of ROS.

Testing and Integration:

• Bring up;
• Testing and debugging;
• Deployment;
• Integration.

Featured Projects

Work that highlights the incredible technologies, solutions, and products EnCata developed.

Arrow backArrow forward

Autonomous snooker robot

The autonomous snooker robot is a device that serves as a trainer during a game of pool. The robot can work as a trainer, against a human, or in tandem with them. The kicking mechanism replicates a human kick's dynamics.

View more

Autonomous Drone Station

EnCata delivered UAV engineering services, designing and manufacturing an autonomous drone docking station with charging, climate control, and positioning systems. The product supports surveillance, delivery, and inspections in Arctic to desert conditions.

View more

Custom Smart Beverage Pourer

EnCata supported a startup as an engineering contractor, developing a smart beverage pourer for bars that meters each pour in real time, connects to POS and mobile apps, and enables NFC payments — from PoC to MVP. All IP belongs to the customer.

View more

Custom Thermal Manikin Testing System

EnCata developed a thermal manikin testing system to evaluate fire-protective clothing. The system features high-efficiency thermal panels, a mobile manikin with 180° rotation, and a crane-beam mechanism adapted to the facility’s space and ventilation layout.

View more

Product Development Technology Stack

• STMicroelectronics,
• NXP
• Nordic
• Texas Instruments (TI)
• GD
• JL
• Linux Embedded
• C /C# / C++
• VHDL / Verilog
• Python
• ASM
• WiFi
• BL/BLE
• NB-IoT
• 3G/4G
• GPS/LORA
• NFC
• SubGH
• UWB
• SB, SPI
‍• I2C, LVDS
• RS232/485
• CSI, DSI
• SD/SDHC/MMC
• CAN, I2S
• Ethernet, 1-Wire
• UART, UIPI

Want to develop a custom solution?

Talk to an Expert

Our development cycle

  1. • Selection of ready-to-use libraries and implementation of third-party software stacks.
  2. • Embedded system architecture development.
  3. • Firmware programming and coding.
  4. • Code testing.
  5. • Documents preparation.
  6. • Requirements elicitation and analysis.

Why EnCata?

01

All-in-house services

Our team is able to work not only on firmware. EnCata’s electronics engineers will develop and manufacture prototypes of printed circuit boards on which this firmware can be debugged. Our industrial designers will realize your vision of the product design. Design engineers will develop enclosures for printed circuit boards based on your vision and design actuators. You can order the first batch of your product for testing in focus groups or for sale to early adopters.

02

Cross-domain expertise

At EnCata, you can get a high-quality assessment and services based on any of the Cynefin Model systems.We develop from small user devices to complex analytical equipment. Our portfolio includes 350+ projects from 20 industries. The accumulated expertise from multiple industries enables us to find unconventional solutions for complex, confusing, chaotic projects.

03

We focus on your business

EnCata has 7 years of experience working on projects for startups, SME and large businesses. Our clients are from the USA, South Korea, Saudi Arabia, Sweden, Canada, Germany, Switzerland, Nigeria, South Africa, Kazakhstan. We have experience working with various business models and corporate cultures, which enables us to rapidly adapt to your business processes and concentrate on the end result.

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FAQ

At EnCata, what kinds of contracts do you use? Is it a fixed-term or an agile contract?
Can you provide me with a certification of competence?
What level of training do your specialists have?
Is it possible for us to cooperate with EnCata’s team?
Is it possible to discuss the project with your technical team?
Can EnCata facilitate mass production?
Do you sign NDAs?
Patent or Develop first?
Does EnCata outsource electronics services?
Do you write program code, either software or firmware?
Are there hardware engineers in your team?
What should I do now that I've approached you with my project idea?
Can EnCata help me with fundraising?

services

Hardware DevelopmentElectronics DevelopmentFirmware DevelopmentMechanical EngineeringComputer SimulationsIndustrial DesignDesign for ManufacturingRapid PrototypingFeasibility StudiesLow Volume Manufacturing

About encata

Our StoryOur PartnersNews & EventsPartnership Opportunities

Resources

PortfolioBlogFor SMEsFor StartupsProcessesFAQ
ENCATA LOGO
EnCata 2008 - 2026 © All rights reserved /
Privacy Policy
EnCata, Ltd

START A PROJECT WITH ENCATA

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