Project Background: Turkish Customer Needs Full System PCB Reproduction
Marine electronics—especially devices with GPS tracking and antenna systems—have grown increasingly popular in recent years. These technologies provide essential directional support for vessels navigating at sea. Our recent collaboration involved manufacturing two complementary PCBs for a Turkish client: a main control board and a satellite antenna board.
The customer approached us after their in-house engineer departed. With the original product in need of an upgrade, our team provided end-to-end technical support including:
- Reverse engineering (copy board)
- Chip decryption
- Circuit redesign
- Sample manufacturing and PCBA production
Step-by-Step: From Sample to Mass Production
1. Board Sample Evaluation and Reverse Engineering
We received two physical PCB samples and assessed the complexity and cost of reverse engineering. By identifying and analyzing the main chips on both boards, we successfully decrypted the embedded firmware and reconstructed full documentation, including:
- Gerber files
- BOM list
- Circuit schematic
2. Circuit Adjustment and Client Confirmation
Per customer request, we made minor circuit and voltage modifications to the original schematic. Updated files were shared with the customer, and once approved, we began PCBA sample production.
Technical Specifications: Main Board and Antenna Board
Main Control Board
- Dimensions: 150mm x 80mm
- Layers: 4-layer FR-4 PCB
- Surface Finish: Lead-Free HASL
- Solder Mask: Matte black
- Silkscreen: White
- Panelization: 2-in-1 panel with V-cut
- Special Feature: Blind via used in design
Satellite Antenna Board
- Dimensions: 80mm diameter (round board)
- Layers: 2-layer FR-4 PCB
- Surface Finish: Lead-Free HASL
- Solder Mask: Matte black
- Silkscreen: White
Component Assembly & Quality Control
Both PCBs require double-sided assembly and are populated with numerous electronic components:
Main Board Assembly
- Over 100+ components, densely packed
- Includes GPS tracking module, multiple micro-switches, and a signal-sensing circuit
- All angles for switches and capacitors must match original samples
- A large screw interface is used to connect the control board to the external remote device
Antenna Board Assembly
- Features high-value inductors and difficult-to-source passive components
- Includes multiple ICs, capacitors, and two metal screws to attach securely to the main system housing
Final Product Function and Integration
The customer provided a complete shell assembly, showing both boards enclosed in a sleek marine electronics casing.
- The GPS system on the main board ensures real-time satellite positioning
- The antenna board senses orientation and motion, guiding the vessel via consistent signal tracking
- This dual-PCB setup is key to marine travel, helping ships maintain safe, accurate navigation
Why Choose Us for PCB Cloning and Marine PCBA Manufacturing?
Our professional team handled everything—from board copying and chip decryption to custom modification and PCBA sample delivery. The boards were produced under strict IPC Class 2 standards, with full attention to quality control, precision alignment, and advanced assembly requirements.
Looking for reliable PCB reverse engineering, custom antenna control boards, or full-system PCBA manufacturing? Contact us today to get started—our engineers are ready to support your project from concept to completion.
