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Hardware Manufacturing & Engineering

Hardware Manufacturing & Business Technology Devices

Hardware is the work most software companies pretend not to do — because hardware does not forgive shortcuts the way software does. Mutex Systems delivers hardware engineering across IoT, embedded systems, PCB design, firmware, point-of-sale terminals, industrial automation, and edge AI devices. Where digital meets the physical world.

Shipped devices in shops, hospitals, factories, vehicles, and field operations across the UK, Pakistan, and the GCC — including the hardware behind Mutex Fintech POS.

Standards & Certifications We Build To

  • ISO 9001 quality management; ISO 14001 environmental management
  • ISO 13485 medical device QMS; IEC 62304 medical software; IEC 60601
  • IEC 61508 functional safety; IEC 62443 industrial control security
  • CE Marking — Radio Equipment, LV, EMC, RoHS, Machinery Directives
  • FCC Part 15; CISPR and ETSI EN 300 for radio emissions compliance
  • RoHS and REACH for hazardous substances and chemical compliance
  • IPC-A-610 acceptability standards for electronic assemblies
  • FIPS 140-3 for cryptographic modules in security-sensitive hardware

Who We Build Hardware For

  • Retail operators rolling out point-of-sale terminals across stores
  • Hospitality groups deploying self-service kiosks at scale
  • Manufacturers instrumenting production lines with industrial IoT
  • Healthcare providers building ISO 13485-backed medical devices
  • Logistics businesses fitting asset trackers to fleets and shipments
  • Energy companies monitoring remote and distributed infrastructure
  • Fintech operators rolling out crypto-ready payment terminals
  • Startups taking a hardware product from prototype to production run
Twenty-One Core Services

Custom Hardware Manufacturing Across the Full Product Lifecycle

IoT device engineering, embedded systems, firmware, PCB design, POS terminals, industrial automation, edge AI, hardware certification, and new product introduction.

IoT Device Engineering

Connected devices from concept to production

Full-lifecycle IoT device engineering — from connectivity architecture to cloud integration — designed to survive the real environments devices actually operate in.

  • MQTT, CoAP, LoRaWAN, NB-IoT, Wi-Fi, BLE connectivity
  • Edge processing, OTA update, and remote management
  • Cloud integration — AWS IoT, Azure IoT Hub, Google Cloud IoT

Embedded Systems Development

Microcontroller-based products and modules

Embedded systems built for the constraints that matter — power budget, memory footprint, real-time response, and long-term maintainability.

  • STM32, ESP32, nRF52, Arduino, and Raspberry Pi platforms
  • RTOS (FreeRTOS, Zephyr) and bare-metal firmware
  • Low-power design for battery-operated and energy-harvesting devices

Firmware Engineering

Real-time, low-power, and safety-critical firmware

Firmware written to be maintainable by a team that did not write it — documented, unit-tested, and version-controlled from the first commit.

  • Real-time operating system integration and driver development
  • Hardware abstraction layers for portability across MCU families
  • OTA update subsystems with rollback and integrity verification

PCB Design & Assembly

Schematic, layout, prototyping, and small-to-medium production

PCB design from schematic capture through layout, design rule checks, and prototype assembly — with DFM considered from the first layer stack decision.

  • Altium Designer and KiCad schematic and layout
  • Multi-layer, high-speed, and mixed-signal PCB design
  • Prototype and small-to-medium production assembly coordination

Industrial Design & Enclosures

Mechanical design, materials selection, human-factors

Enclosure design that satisfies IP ratings, thermal requirements, assembly constraints, and the need to look appropriate for the environment it operates in.

  • IP-rated enclosure design for indoor and outdoor environments
  • Thermal management and heat dissipation design
  • Human-factors and ergonomic design for operator-facing devices

Point-of-Sale Terminal Engineering

Card and crypto-ready POS hardware

The hardware behind Mutex Fintech POS — our own crypto-ready payment terminal. Card-present, NFC, and QR payment hardware engineered for reliability in high-transaction environments.

  • Card-present (EMV), NFC contactless, and QR payment support
  • Crypto settlement integration and secure element design
  • Offline operation mode with transaction queue and sync

Self-Service Kiosk Engineering

Retail, hospitality, and public-sector kiosks

Kiosk hardware designed for the environment it will actually live in — vandal resistance, 24/7 reliability, remote management, and accessibility compliance.

  • Touchscreen, barcode, NFC, and payment-integrated kiosks
  • Vandal-resistant enclosure design and tamper detection
  • Remote monitoring and OTA software update capability

Smart Building Devices

Sensors, controllers, and gateways for commercial property

Smart building device design for occupancy, energy, environmental, and access management — integrated with BMS and cloud analytics platforms.

  • Occupancy, temperature, CO2, and air quality sensors
  • Access control panels and visitor management hardware
  • BACnet, Modbus, and KNX protocol integration

Industrial Automation & PLC Integration

Shop-floor automation and SCADA connectivity

Industrial IoT hardware that bridges the gap between the plant floor and digital systems — connecting legacy PLCs and SCADA systems to modern analytics and control platforms.

  • OPC-UA, Modbus, PROFINET, and EtherNet/IP connectivity
  • IEC 62443-aware security design for industrial control systems
  • Edge gateway hardware for shop-floor data capture

Wearables & Medical Devices

ISO 13485-aware design and IEC 62304 firmware

Medical-grade device design aligned to ISO 13485 quality management and IEC 62304 software lifecycle requirements — designed for the standards, not around them.

  • ISO 13485 QMS-aligned design and production controls
  • IEC 62304 software lifecycle and IEC 60601 electrical safety
  • FDA and MHRA submission support documentation

Edge AI Devices

On-device inference for vision, audio, and sensor analytics

Edge AI hardware that runs inference locally — reducing latency, cloud costs, and privacy exposure compared to cloud-dependent AI deployments.

  • NVIDIA Jetson, Google Coral, Hailo, and Raspberry Pi AI
  • Microcontroller-class neural accelerators — STM32, Nordic
  • TensorFlow Lite and ONNX model optimisation for edge deployment

Asset Tracking & Telematics

GPS, BLE, LoRaWAN, NB-IoT trackers for fleet and logistics

Asset and fleet tracking hardware designed for long battery life, reliable connectivity in poor signal environments, and tamper-evident installation.

  • Multi-technology positioning — GPS, BLE beacon, LoRaWAN, NB-IoT
  • Solar-assisted and long-life primary cell power designs
  • Fleet management platform integration with real-time dashboards

Sensor Networks

Environmental, industrial, and structural monitoring at scale

Sensor network hardware and infrastructure for large-scale monitoring deployments — designed for long-term reliability in demanding physical environments.

  • Mesh network topologies for dense sensor deployments
  • Environmental hardening for temperature, humidity, and vibration
  • Gateway hardware with edge analytics and cloud forwarding

Custom Tooling & Jigs for Manufacturing

Production tooling and quality control fixtures

Purpose-built tooling and test fixtures for production lines — designed to speed up assembly, reduce operator error, and ensure consistent quality at volume.

  • Assembly jigs and fixtures designed for the specific product
  • In-circuit test (ICT) and functional test fixture design
  • Tooling design for DFM — reducing assembly time and defect rate

Device Management & OTA Update Platforms

Cloud-managed firmware updates and device telemetry

Device management infrastructure that keeps firmware current and devices observable — without requiring physical access to deployed units.

  • Secure OTA firmware update with rollback and integrity check
  • Device fleet management — provisioning, health, and telemetry
  • Integration with AWS IoT, Azure IoT Hub, and custom backends

Hardware Certification Support

CE, FCC, RoHS, and compliance from schematic stage

Design-for-compliance from the schematic — catching certification risks before they become costly redesigns at the test laboratory.

  • CE Marking — Radio Equipment, LV, EMC, RoHS, Machinery Directives
  • FCC Part 15 and CISPR/ETSI EN 300 radio compliance
  • Test laboratory liaison and declaration of conformity preparation

Reverse Engineering & Legacy Hardware

Recovering, replacing, or extending discontinued hardware

Legacy hardware revival — recovering schematics from physical boards, replacing obsolete components, and extending firmware for devices whose original design files no longer exist.

  • Schematic recovery from physical PCB analysis
  • Obsolete component identification and modern replacement
  • Firmware extraction, analysis, and extension

Hardware Testing & QA

Environmental, EMC, vibration, drop, and lifecycle testing

Hardware QA beyond bench testing — environmental chambers, vibration rigs, drop tests, and EMC pre-compliance testing to reduce the risk of first-article certification failures.

  • Environmental testing — temperature cycling, humidity, IP ingress
  • Mechanical testing — vibration, shock, and drop simulation
  • EMC pre-compliance and burn-in testing for production lots

Supply Chain Advisory

Component sourcing, BOM optimisation, and risk reduction

Supply chain guidance for hardware products — component selection that balances cost, availability, lead time, and long-term lifecycle risk.

  • BOM review and component alternates strategy
  • Long-term supply risk identification and mitigation
  • Contract manufacturer selection and quality audit support

Cryptographic Hardware Integration

Secure elements, TPMs, and HSM integration

Hardware-rooted security for devices handling sensitive data or operating in adversarial physical environments — cryptographic keys that cannot be extracted from a stolen unit.

  • Secure element integration — ATECC608, SE050, SLB 9670 TPM
  • FIPS 140-3 compliance for cryptographic module requirements
  • Secure boot, measured boot, and remote attestation design

Hardware Bring-Up & New Product Introduction (NPI)

From bench prototype to first production run

New product introduction support from first prototype bring-up through design validation, production validation, and the first production run.

  • Prototype bring-up, debug, and design iteration support
  • DVT and PVT phase support with structured test plans
  • First production run QA, yield analysis, and process improvement
What You Receive

Complete Hardware Package — Files, Tests, and Certification Evidence

Every hardware engagement delivers a complete technical package — design files in your hands, test evidence ready for certification submission, and manufacturing documentation your production partner can act on without us in the room.

Discuss a Hardware Project
  • Feasibility and hardware specification document with risk analysis
  • Schematic and PCB design files in Altium Designer or KiCad formats
  • Firmware source code with inline documentation and test coverage
  • Bill of materials with component alternatives and sourcing recommendations
  • Prototype and design validation test reports with pass/fail evidence
  • Certification test evidence and CE/FCC declaration of conformity
  • Manufacturing and assembly guidelines for production partners
  • Device management platform documentation with OTA update procedures
How We Engage

From Feasibility to Shipped Product

Hardware engagements follow a five-phase model. Most begin with a paid feasibility and specification phase — two to four weeks — producing a requirements specification, BOM estimate, and fixed-scope quotation for subsequent phases.

  1. 01

    Feasibility & Specification

    Paid, 2–4 week phase. Requirements specification, architecture sketch, BOM estimate, risk analysis, and fixed-scope quotation.

  2. 02

    Design & Schematic

    PCB schematic, layout, firmware architecture, enclosure design, and DFM review — iterating with you at each major design checkpoint.

  3. 03

    Prototype & Validation

    Prototype bring-up, functional testing, pre-certification testing, and design iterations — until DVT criteria are met.

  4. 04

    Production & Support

    First production run, certification, OTA infrastructure setup, and ongoing hardware support and firmware maintenance.

FAQs

Common Questions About Hardware Manufacturing Services

Straight answers about IoT device engineering, PCB design, hardware certification, and how hardware projects engage.

What hardware does Mutex Systems actually build?

IoT devices and connected products, embedded systems and microcontroller-based products, industrial sensors and gateways, point-of-sale terminals (including the Mutex Fintech POS with crypto settlement capability), self-service kiosks, smart-building devices, asset trackers and fleet telematics devices, wearables, medical-grade devices, edge AI hardware, and custom tooling and jigs for production lines. We also provide PCB design, firmware engineering, and full-lifecycle support from concept through manufacturing.

Can you take us from concept to shipped product?

Yes. Our hardware engagements run across five phases: feasibility and specification, design and schematic, prototype and validation, production run, and ongoing support and OTA update. Most engagements begin with a paid feasibility phase — two to four weeks — that produces a requirements specification, architecture sketch, BOM estimate, and risk assessment. This gives you a written fixed-scope quotation before any significant engineering investment is made.

Do you do PCB design and assembly?

Yes. We use Altium Designer and KiCad for schematic capture and PCB layout. Our PCB work covers multi-layer designs, high-speed digital, RF, mixed-signal, and power electronics. For prototype assembly we work with trusted electronics manufacturing partners and can coordinate small-to-medium production runs. DFM (design for manufacture) considerations are built into the layout process rather than addressed as an afterthought before production.

Can you support CE, FCC, RoHS, and other hardware certifications?

Yes. We design for compliance from the schematic stage — catching EMC, safety, and radio issues before they become expensive failures at the test laboratory. We provide CE Marking support across the Radio Equipment Directive, Low Voltage Directive, EMC Directive, RoHS Directive, and Machinery Directive depending on product type. For FCC we support Part 15 compliance and test laboratory coordination. We manage all test laboratory liaison and prepare the technical file and declaration of conformity.

Do you build IoT devices with cloud connectivity?

Yes. Our hardware and cloud practices work together on IoT projects — the hardware team designs the device and its connectivity, and the cloud team builds the backend infrastructure, device management platform, and data analytics layer. We have delivered IoT projects connecting to AWS IoT Core, Azure IoT Hub, and custom MQTT brokers, using LoRaWAN, NB-IoT, Wi-Fi, BLE, and cellular connectivity depending on the power, bandwidth, and range requirements of the specific application.

Can you reverse-engineer or extend legacy hardware?

Yes. Legacy hardware work typically involves recovering schematics from physical PCB inspection and analysis, identifying obsolete components and sourcing modern alternatives, extracting and analysing existing firmware where required, and extending the hardware and firmware for new requirements. This is common for manufacturing clients with production equipment whose original supplier has ceased trading, or for clients acquiring businesses with undocumented hardware assets.

Do you build edge AI devices?

Yes. Our edge AI hardware work covers NVIDIA Jetson platforms for computer vision and inference-heavy workloads, Google Coral with Edge TPU for power-efficient inference, Hailo accelerators for embedded vision applications, and microcontroller-class neural accelerators including STM32 with CubeAI and Nordic Semiconductor. We handle model optimisation for edge deployment using TensorFlow Lite and ONNX, as well as the hardware bring-up and integration of the inference pipeline with the surrounding device firmware.

Let's Talk

Ready to Build Your Hardware Product?

Send us a brief — what you are trying to build, what environment it will operate in, and any constraints around connectivity, power, certification, or volume. Within two working days you will receive a written response and a proposed feasibility scope.

No commitment requiredResponse within 24 hoursPaid feasibility phase first