The Challenge
The original PCB inside a legacy remote entry system had been discontinued. No replacement was available from the original manufacturer, and sourcing a like-for-like board through generic channels was not possible. The owner needed a functionally identical board that would fit the existing housing without modification. The only option was to start from the existing hardware and work backwards.
Our Approach
ProtoGT reverse-engineered the original PCB to capture everything needed to reproduce it. Working from the physical board, we traced the full schematic, identified every component, and recorded the mechanical constraints imposed by the original housing.
From that foundation, we produced a compatible replacement design and managed the full production process in-house:
- Full schematic capture from the existing board
- Component identification, including obsolete or generic part substitution where necessary
- PCB layout designed to match the original mechanical footprint
- Small batch manufacture using direct-to-manufacturer sourcing
- Functional testing of every board before delivery
Each board was delivered ready to install into the original remote housing with no modifications required.
The Result
The client received a working batch of compatible replacement boards that restored full functionality to hardware they could not otherwise repair. The reverse engineering process produced a documented design that can be reproduced again if further boards are needed.
This project demonstrates how reverse engineering can extend the working life of legacy electronics when original parts are no longer available, whether for a single unit or a small production run.