Hardware development company

EnCata is an outsourced product development company. Our team is focused on hardware engineering and provides full cycle product development: industrial design, mechanical and electrical engineering, prototyping and design-for-manufacturing.

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New product development is a challenge

Developing a new product is one of the most exciting and challenging things our team loves to do. Launching a hardware product requires business skills and engineering expertise. Success requires thinking through the product life cycle: from idea to market launch. Such competencies are rarely found in one single entrepreneur.

We have assembled a team of engineers who are ready to become your technical director and tailor the development process to the business goals of the project or product. We have worked in industries ranging from IoT products, robots, industrial equipment and digital hardware to consumer electronics and wearable devices. We will share our experience of the different stages of product creation: strategy, idea validation and  going into mass production.

60+ Engineers

We act as your extended R&D team which is faster than hiring engineers locally. The breadth of our technical expertise is unique.

Development Speed

Our dedicated team is ready to scale up quickly. We utilize AGILE lean development process that leads to 30-50% faster delivery.

Burn rate


Our development location enables us to be cost-effective and deliver premium R&D and engineering services at 1/3 of the price compared to that of in N-W Europe and USA.

NPD, Hardware development

New Product Development Strategy

New product development consists of stages that should not be skipped. Choosing an evaluation methodology may not seem important, but it formalises the goals and ideas, and ensures that important steps are not being missed. For products that are based on breakthrough innovation, we use the TRL methodology. Our team works from TRL-2 to TRL-8. We will conduct a feasibility study to assess market prospects, as well as prepare a POC to validate the technology's performance in front of investors. Our technologists will refine the documentation of the TRL-7 prototype to reduce the cost or improve the quality of the product.

For products that will conquer the mass market, evaluation in the validated testing stages is more appropriate. Looks-like-prototype will help the entrepreneur conduct customer development far more than printed circuit boards and wires scattered around the desktop - works-like-prototype.

Reverse Engineering

Using reverse engineering gives obvious benefits. Since you are not reinventing the wheel during the mechanical design stage, you are both saving time and reducing the costs. Reverse engineering is not a good option for the main features of a product. In this case, your product will always fall  behind your competitors.

mechanical engineering DFM

Mechanical Engineering

Mechanical Engineering is not only about the development of products that will be mass-produced, but includes both Components design and Enclosure design and development. Starting new projects, we always take into consideration these two parts of the customers’ product.

Custom electronics design

Electrical Engineering

The use of Arduino and Rapsbery Pi can be attributed to rapid prototyping techniques in electronics. With these devices, you can develop something functional over just one weekend. Unfortunately, these prototypes can not be used as a basis for further development. The printed circuit boards will have to be redone, but the firmware will remain unchanged if the architecture is designed correctly.

Firmware Development

Modern smart devices can not function without firmware and embedded systems. Our company works at all stages of creating a new product. Therefore, embedded systems development is a significant part of our everyday work. For simple devices, we prefer to design with controller firmware using C and for multifunctional devices, we like to use Linux Embedded.

Feasibility Studies

When developing new products with improved features, it is important to understand what benefits these improvements will give your business, as well as how this will affect the financial performance. In order to not spend a huge budget on developing a product that will be uncompetitive, we can conduct a preliminary study. Our engineers will conduct a technical analysis of competitors to understand what level of technology is needed to gain a competitive advantage. Our business analysts will calculate the preliminary financial indicators thus you can make an informed decision about the start of the project.

Industrial Design

Rapid prototyping is used to validate industrial product design solutions. The prototype will give far more information than the model on the screen. Despite this, when creating industrial design, it is better to focus on mass production technologies. Not all prototypes that are 3D printed can be produced in thousands of pieces.

Enclosure Design

Rapid prototyping technologies allow you to quickly model and produce an electronic component housing. This is important for products in which the enclosure is constantly interacting with the user. The user may not even notice that he is holding a prototype if the finishing is done well. For industrial applications where the enclosure has protective functions, the use of standard enclosures may be better suited. This will save the budget for design and mass production.

Proof-of-Concept Prototyping

When developing new products, engineers most of the time needs more data and insights. Rapid prototyping methods can be used to quickly check technical solutions for device ergonomics and assembly manufacturability. Unfortunately, the mechanical properties of prototypes made by rapid prototyping methods are very different from those of industrial materials. Sometimes, it is better to develop an inexpensive layout, which, in terms of characteristics and manufacturing technologies, will be close to a ready-made solution only in terms of functionality. In this case, design engineers specifically design a prototype, prepare testing methods and process the information received.

Mold Manufacturing & Tooling

Rapid prototyping technologies primarily reduce the budget and lead time for the first product sample. This is because the design and manufacture of injection molding presses are expensive and time-consuming. Rapid prototyping reduces the risks when going into mass production, but does not exclude the investments in mold development.

NPD, Hardware development

LEAN approach and prototype development

We love projects where we can test the workability of our ideas. We have our own production facility for this purpose. It allows us to be flexible when designing products. We are able to design and produce a mock-up to test a critical element of a prototype in just a couple of days,  without having to draw drawings and negotiate prices with production service providers. The design office and workshop operate according to the LEAN principles. There is a constant question in the team: does our work add value to the product and is it useful for the customer?

During the development, we always ask the customer about the main idea of the product, its innovation and value for the end user. Our engineers then create the concept, adding their expertise to make the product reliable and inexpensive to manufacture. On the other hand, the project team often recommends removing parts from the assembly that do not carry any useful functions, but reflect the legacy of previous models or competitors' designs. The requirements identification and conceptual design phases create a solid foundation for the entire project. Once we have created a concept and are confident that it meets the customer's goals and requirements, we move on to detailed design, prototyping, design enhancements, prototyping replications and tests.When we have passed the test, we develop drawings and other design documents. With the documentation package, our customer is ready to approach contract manufacturers and start mass production. We can manufacture a batch of devices ourselves, for the first sale.

Product Development Technology Stack

PCBA design

PCB board design: Analog, digital, optical, and RF design
Board layout: mixed signal / high speed / high layer count
Flex-PCB design

Battery management icon

Battery management systems (BMS)
AC/DC and DC/DC design for high battery life

Electronic circuit design and schematic capture
Design for manufacturability/testability (DFM/DFT)

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wireless interfaces design

Wireless systems:  Bluetooth® (BT) & LBE,  Wi-Fi/WLAN (802.11), RFID, NFC

Custom electronics design

STM 32,  NXP chips, Nordic chips, Texas Instruments (TI)
8/16/32 bit MCU development

Arduino family
Raspberry family

Cellular: 2G, 3G, 4G, GSM, GPRS
GPS / Beidou /
NB-IoT,  LTE Cat-M


PID controllers
Physical algorithms development

FPGA design

FPGA development
RTL coding and FPGA simulations, synthesis, place and route

ico IC design

IC design & Power electronics
Invertors and solar power management

interfaces electronics

Interfaces: USB, SPI/SSP, I2C, LVDS, RS232/485, SD/SDHC/MMC, Ethernet, PoE, 1-Wire, CAN, I2S, AC97

Engagement Models

We focus on the entire product/service lifecycle, from concept to implementation to market launch.  EnCata’s knowledge, resources and innovation development expertise allow our Clients to develop and expand their businesses faster and leaner.

Some hardware Projects we delivered

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

Industries We serve

Our hardware engineers are focus on the entire product/service lifecycle, from concept to implementation to market launch.  EnCata’s knowledge, resources and innovation development expertise allow our Clients to develop and expand their businesses faster and leaner.

FAQ related to Product development

At EnCata, what kinds of contracts do you use? Is it a fixed-term or an agile contract?

EnCata works with both fixed term and agile contracts.

Can you provide me with a certification of competence?

EnCata employs around 30 engineers with Master's and PhD degrees in electrical and industrial design, mechanical engineering, prototyping and manufacturing from European universities. Each employee is an expert in his or her field.

What level of training do your specialists have?

The majority of specialists are of middle or senior levels. Their range of influence is broad enough to encompass the entire new product lifecycle. Our specialists resolve legal and certification difficulties during the concept stage, optimize production costs during the 3D model development process and create necessary documentation for firmware support. Juniors make up only 15% of the team. They constantly upgrade their qualifications under the supervision of seniors.

Is it possible for us to cooperate with EnCata’s team?

EnCata is always willing to work with its client. We have everything we need to create a collaborative site. Both parties can work on the project simultaneously. The Customer, for instance, and his/ her team designs the electronics while we work on the enclosure. When teams work together to achieve a fantastic result, it is always a win scenario.

Is it possible to discuss the project with your technical team?

EnCata’s team is always willing to discuss all the necessary details about the project proposed. Our full-fledged team of professionals will interrogate you until both parties are satisfied with the procedures necessary to complete the job.

Can EnCata facilitate mass production?

It certainly can. For any product, EnCata creates a design documentation package and a process documentation package that is suited to the production. It should be noted, however, that the technologists at the customer's chosen plant may make changes or impose their own requirements on the documentation design. EnCata, in turn, makes it easier for the client and the technologist to communicate. EnCata does not mass produce, although it can undertake small-scale production at the request of customers.

Do you sign NDAs?

Yes. As a highly professional design and engineering firm, we make sure that all discussions with our clients and all information regarding your invention, idea and other proprietary information are kept confidential.

Patent or Develop first?

We follow a LEAN approach in product and business development and thus we strongly recommend patent filings only after you are  at least part-way through development. This is because patenting is expensive and early patents can already become obsolete or irrelevant later in the development phase. Typically, EnCata's work generates many patentable opportunities for our clients  and the best strategy is to file patents at TRL-7, i.e. when early beta prototype is ready and when a startup is ready to start batch production and marketing.There is, however, another strategy, which is to use provisional patents which can be loose and are not to be disclosed to the public for 18 months. These are much less expensive and time consuming, generally costing below $500.

EnCata will always sign a Non-Disclosure Agreement and keep your intellectual property confidential during the development phase and then we can recommend several third-party patent attorneys when the time is right.

Does EnCata outsource electronics services?

Our in-house professionals handle almost all electronics work, including interface design, protocol development, communication design, schematic design, PCB Design, Firmware design and battery management. If the Customer requires a service that Encata does not supply, we have partners that can meet that need.

Do you write program code, either software or firmware?

We certainly do. EnCata employs electronics specialists who deal with low-level firmware. We also have experts on staff who can implement high-level software code.

Are there hardware engineers in your team?

EnCata employs 12 mechanical and industrial designers and 10 electrical engineers with experience in hardware and firmware. Our team consists of middle and senior level engineers, who have 5+ years of field expertise and have already completed more than 300 projects.

What should I do now that I've approached you with my project idea?

1. Once you have approached us with the project, we conclude the NDA and send the information to the Sales Manager for further evaluation and project planning.
2. The Sales Manager or Sales Engineer will contact you to clarify your goals, requirements and tasks to accomplish. This process is very close to business analysis. When the details are agreed with you, a cost estimate and a quotation are prepared.
3. If you accept the quotation, we will prepare a Technical design specification to document scope of work and requirements and conclude an agreement.
4. After we've signed the agreements, we'll assign you a Project Manager who will gather a project team and report on the project progress.

Can EnCata help me with fundraising?

We do indeed help with fundraising through our large business network. However, we typically recommend startups to our partner VCs after we have done some work for the startup and learned more about the team and their core technology. This feedback and recommendation is of great value to all of the friendly VCs as it saves them much time and effort for due diligence.

Have a project to do? Reach out to EnCata team

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