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Designing Embedded Computers for Rugged Applications

Application Articles

Building Automation
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Lung Simulator
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Custom Products and Solutions

Diamond Systems has an extensive history of providing custom design and manufacturing services for embedded boards and systems. Here is a select set of products demonstrating our capabilities. Contact us to find out how we can help you achieve success on your next embedded computing project.

VME SBC for Product Life Extension

A major US defense contractor needed to extend the lifecycle of an in-vehicle monitoring system when their current SBC became unmanufacturable due to component obsolescence. The new design incorporated the complete circuits of two Diamond standard products (an SBC and an I/O board) as well as a third party MIL-STD-1553 circuit. The use of existing proven designs shortened the development time considerably, and the customer achieved significant performance improvement as well. A novel feature of this board is the ability for the embedded Windows 10 OS to survive instant shutdown from a power switch without corruption.


VME form factor SBC with Bay Trail processor, 8GB RAM soldered down, dual CAN ports, dual channel MIL-STD-1553 network, and direct-soldered 64GB flashdisk



Nvidia Jetson Carrier for Rugged System

A well-known supplier of rugged computer systems was developing a new generation of products based on Nvidia Jetson GPU technology. They chose Diamond Systems to design and manufacture the carrier board with custom I/O that serves as the heart of their system.


Nvidia AGX Xavier carrier board for compact rugged computer system



Custom Ethernet Board for Subway System

The customer was upgrading the network in a major metropolitan area and needed to add Ethernet ports to a custom computer system. Diamond designed this 2-port 10/100 Ethernet adapter using PCI interface and built several thousand units over a period of several years. For cost reasons this product was manufactured at our Taiwan facility.


Dual-port network card with PCI-104 interface for subway trackside system



I/O Board Set for Railway Locomotive

A long running program to upgrade freight locomotive dashboards uses two boards from Diamond Systems. One is a Standard Product Variant, consisting of modifications to a standard PC/104 CAN board, while the other is a full custom PC/104 board providing 8 serial ports in a combination of isolated, non-isolated, and TTL level signaling. During the long product lifetime, as components became obsolete, Diamond redesigned the board with the latest available technology to maintain the exact same form, fit, and function, with no change required to the assembly, cabling, or software of the main system.


Custom CAN and serial port PC/104 modules for a locomotive dashboard



Ruggedized SBC for Weapons Station

Diamond’s Athena SBC was chosen as the controller for the CROWS (Common Remote-Operated Weapons Station) that was mounted on thousands of US and allied military ground vehicles. Over 18,000 ruggedized boards were delivered during the life of the program. Customizations included changing connectors, BGA underfill for ruggedization, hardwired configuration, custom BIOS, conformal coating, and full temperature cycling of each unit.


Original Athena SBC


Modified and ruggedized version



Rugged System for Pilot Jet Trainer

A manufacturer of model-size jets used for pilot training needed a rugged computer system with a variety of I/O in high quantities, along with special power features. Diamond designed and built a rugged system based on our SabreCom product family. The case was increased in size to accommodate 7 PC/104 boards.


Rugged systems with 7 PC/104 boards and extensive I/O



Custom I/O-rich Embedded Computers for Traffic Control

These compact systems are used for roadside traffic signage. The one on the left integrates 6 PC/104 boards into a 5" deep case, while the one on the right contains 2 boards in a 1.7" deep case. The systems use our Pandora enclosure system and include custom-designed "panel I/O boards" that eliminate most internal cables, resulting in a compact and reliable design.


Compact, cost-effective embedded systems using PC/104 technology



Custom Ethernet Switch

A customer building a miniature rugged Ethernet switch chose Diamond's EPSM-10GX4 miniature, rugged Ethernet switch module as the core of their system. They further engaged with us to design and manufacture a custom carrier for the switch that accommodated their particular shape, I/O, and internal cabling needs.


Carrier board for rugged Ethernet switch



Your Solution Can Be Next!

Contact Diamond Systems today to discuss your needs with our technical sales team and find out how we can deliver success for your next embedded design.

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Custom Embedded Computing Solutions from Diamond Systems

Custom solution building blocks Diamond can utilize these proven technologies and capabilities to develop a perfect-fit custom solution with high confidence.

Technology Capabilities

  • x86 CPU design
  • x86 COM carrier design
  • NVIDIA Jetson carrier design
  • ARM COM carrier design
  • PC/104 SBC and I/O design
  • PCIe, PCI, LPC, and ISA buses
  • M.2, mSATA, and SATA-DOM flash memory modules
  • Minicard design
  • Ethernet switches with management software
  • FPGA design
  • PCIe, PCI, LPC, and ISA FPGA cores
  • Power supply design � buck/boost, switching/linear
  • Power filtering � MIL-STD-461/1275/704
  • Power over Ethernet � PSE, PD, Class A and B
  • UPS circuitry
  • Battery charging
  • Microcontroller firmware development


I/O Capabilities

  • Analog input � voltage and current
  • Analog output � voltage and current
  • Autocalibration with software/hardware control
  • Serial ports � RS-232, RS-422, RS-485
  • Ethernet ports
  • USB 2.0 / 3.0
  • Display technologies � HDMI, DP, LVDS, VGA
  • Digital I/O
  • Opto-isolated digital I/O
  • Counter/timers
  • Pulse-width modulators
  • Electromechanical relays
  • CANbus
  • MIL-STD-1553
  • Computer audio
  • PC/104, PCI-104, PCIe/104 buses
  • Minicard sockets
  • M.2 sockets


Rugged Design

  • Rugged design � PCB, connectors, and wide temperature
  • Design for wide temperature operation
  • Rugged SODIMM design
  • Soldered memory
  • Soldered flash memory
  • Burn-in testing
  • Temperature testing
  • Shock / vibration testing � MIL-STD-202/810
  • Conformal coating and staking


Systems and Solutions

  • Application-specific form factors and expansion buses
  • Aluminum enclosures and heat sinks
  • Sheet metal enclosures
  • IP67 sealing with gaskets
  • Cable & harness design
  • MIL-DTL-38999 cable assemblies
  • OS board support packages


Business Support

  • Configuration control
  • Lifecycle management
  • Long life programs
  • US and international manufacturing sites