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Industries

Industrial IoT & Industry 4.0 Electronics Solutions

We design industrial IoT hardware, firmware and data pipelines: condition-monitoring sensors, edge gateways (OPC UA, Modbus, MQTT), asset tracking (BLE, UWB) and rugged controllers, designed to IEC 62443 and, where required, IEC 61508 and ATEX/IECEx requirements.

  • IEC 62443
  • IEC 61508
  • ATEX/IECEx
  • OPC UA
  • Modbus
  • MQTT

What we build

What we build for industrial teams

Smart manufacturing systems

Industry 4.0 systems with automation, real-time production monitoring, and digital process control that help raise throughput and reduce quality defects.

Predictive maintenance & asset health

AI-powered condition monitoring that analyzes vibration, temperature, and operational patterns to predict equipment failures before they occur and reduce unplanned downtime.

Industrial IoT (IIoT) networks

Secure, scalable industrial communication networks with OPC UA, MQTT, and Modbus integration, enabling data flow between machines, sensors, and enterprise systems.

Manufacturing analytics platform

Real-time production intelligence dashboards that turn operational data into insights for OEE optimization, quality management, and production planning with customizable KPIs.

Digital twin technology

Virtual replicas of physical manufacturing systems for simulation, optimization, and validation of process changes before implementation, reducing implementation risk.

Energy monitoring & optimization

Energy management systems that identify consumption patterns, detect inefficiencies, and automate load balancing to reduce energy costs across manufacturing operations.

2 more capabilities

SCADA & HMI solutions

Modern, intuitive control systems with mobile-responsive interfaces that give operators real-time visibility and control over industrial processes from any location.

Edge computing infrastructure

Ruggedized edge computing platforms that process data locally for fast response in critical applications while minimizing bandwidth requirements and cloud computing costs.

Applications

Industry applications

Manufacturing

  • Production line monitoring
  • Quality control automation
  • Inventory management
  • Supply chain optimization

Energy & Utilities

  • Smart grid management
  • Energy consumption monitoring
  • Predictive maintenance
  • Resource optimization

Process Industries

  • Environmental monitoring
  • Safety systems
  • Process control
  • Compliance management

Standards

Standards and protocols

IEC 62443

Industrial cybersecurity

Security at every layer for industrial IoT: secure boot, TLS-encrypted communication and mutual authentication, following IEC 62443-4-1 (secure development) and IEC 62443-4-2 (component requirements).

IEC 61508

Functional safety

Hardware and software designed to IEC 61508 requirements for the target SIL, with the safety case prepared for your independent functional-safety assessor.

ATEX / IECEx

Hazardous environments

Electronics designed to the intrinsic-safety requirements of IEC 60079-11 and prepared for ATEX/IECEx assessment by a notified body or IECEx certification body, with wide operating-temperature ranges.

OPC UA, MQTT, Modbus

Industrial protocols

Integration between machines, sensors and enterprise systems over OPC UA, MQTT and Modbus.

How we work

How an industrial IoT project runs

  1. Discovery and architecture

    Requirements analysis, connectivity protocol and cloud platform selection, security architecture and threat modelling.

  2. Development and integration

    Hardware design and firmware, backend APIs and databases, dashboards and the data pipeline.

  3. Pilot

    Installation, telemetry quality, power consumption and support procedures checked under real operating conditions.

  4. Deployment and support

    Device provisioning and fleet management, performance monitoring, security updates and OTA rollouts.

Proof

Industrial IoT case studies

Video poster: “78% less unplanned downtime”, labelled Client-reported, “45 h → 10 h per month”, over an illustrative photo of a vibration sensor node on a motor in a steel plant.

Predictive maintenance for a steel plant23 s · no sound

Video text
  1. 78% less unplanned downtime (Client-reported). 45 h → 10 h per month.
  2. Case study · Industrial IoT. A steel manufacturer, 3 plants in India. Maintenance was purely reactive.
  3. We designed the nodes, gateways, models and dashboard. Sensor node: STM32L4 · ADXL355, LoRa radio. LoRaWAN · IN865 link to the edge gateway: STM32MP1 · TensorFlow Lite, LoRaWAN gateway. Ethernet / Wi-Fi link to the cloud: AWS IoT Core · Grafana.
  4. 10-node pilot → 500+ nodes across 3 plants. 94% fault-classification accuracy (Measured in pilot). Bearing wear · imbalance · misalignment · looseness.
  5. Predictive maintenance for a steel plant. Rapid Circuitry. Discuss your product → rapidcircuitry.com/contact. Reply within one business day · Mutual NDA on request.
  6. The photo is an illustrative image.
Review all case studies

FAQ

Frequently asked questions

Working with Rapid Circuitry

How much does a project cost, and how is pricing structured?

Each project is quoted as a fixed-scope proposal: a statement of work with milestones, deliverables and pricing, sent within 3–5 business days of the discovery call. The price depends on the requirements, how mature the design is, technical complexity, the number of prototype iterations and the validation scope. Longer engagements can also run as a retainer or a hybrid of both. For budgeting before you contact us, our hardware development cost benchmarks and the PCB design, firmware and IoT cost guides give indicative ranges with their assumptions stated. They are planning ranges, not quotes.

How long does a project take?

It depends on the scope and on what already exists when we start. As planning ranges from our cost benchmarks: a single PCB layout takes 2–6 weeks per board and embedded firmware 4–16 weeks. A connected (IoT) product takes 3–12 months from concept to a production-ready design, and a regulated medical device 12–24 months to a 510(k) submission-ready package; from idea to mass production, a typical connected product takes 9–18 months. The proposal sets out a dated milestone plan, and you receive weekly progress updates during the project.

Who owns the intellectual property?

You do. Our contracts assign the intellectual property in the project work product (schematics, PCB design files, firmware source code and documentation) to you on payment, and we hand over the source files, not only fabrication outputs or compiled binaries. The exact terms are set out in the signed agreement for each engagement.

Do you sign NDAs?

Yes. We sign a mutual NDA before any technical discussion of your project. Send your standard NDA or use ours; we return it signed within one business day.

Can you work with clients in the US, Europe and Japan?

Yes. We are based in Hyderabad, India, and work with product teams in India, the United States, the United Kingdom, Germany, Japan, Australia, the Middle East and other markets. Our office hours are 10:30–19:00 India Standard Time (UTC+5:30), Monday to Saturday, and we schedule design reviews across time zones, typically from US Pacific to Central European time. Japan is 3.5 hours ahead of India, so our first four hours overlap the Japanese afternoon. Prototypes and documentation ship by international courier such as DHL or FedEx. Our hardware outsourcing guide covers what to agree before an international project starts.

Do you hand off to manufacturing, and which contract manufacturers do you work with?

Yes. We prepare the manufacturing release package — fabrication and assembly drawings, the BOM with approved manufacturers, programming files and test specifications — and hand it over to the contract manufacturer (EMS) you choose. If you have not chosen one, we help you evaluate candidates through technical capability assessments and a pilot build. See manufacturing support.

Are you ISO 9001 or ISO 13485 certified?

No. Rapid Circuitry does not hold ISO 9001, ISO 13485 or other certificates. Our processes are aligned with ISO 9001:2015, and we design products to the requirements of the standards that apply to them — for example IEC 60601-1 and IEC 62304 for medical devices (with design documentation structured so your ISO 13485 quality system can absorb it) and IEC 61000 for EMC — and we specify IPC-A-610 workmanship classes for assembly. We prepare the product and its documentation for certification testing at accredited laboratories; the certificate or approval is issued for your product by the laboratory, notified body or regulator.

What do you need from me to start?

A short, non-confidential description of the product and what it must do (sensors, connectivity, on-device processing), the target production volume and unit cost, the markets and regulations it must meet (for example FDA, CE or FCC), your timeline, and what already exists: a concept, a proof of concept, schematics, PCB files or firmware. After the NDA, the next step is a 30-minute discovery call with the engineers who would work on the project, followed by the fixed-scope proposal. Send a project brief to begin.

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