Active PCB co-development for parallel motor-control in an interferometer alignment system
An OEM in the semiconductor industry needed to replace a manual alignment tool with a fully automatic solution. PDM joined as a co-development partner with result responsibility, taking the electronics from requirements to a validated active PCB. The outcome: a reliable, integration-ready solution that reduced manual work and helped make performance and quality more predictable.
OUR CUSTOMER
A leading high-tech OEM in the semiconductor industry developing highly complex machines, where interferometer-based measurement systems rely on extremely precise mirror positioning and robust motion-control electronics.
THE CHALLENGE
Manual, sequential mirror alignment
Each mirror had to be calibrated one by one using a manual tool, leading to slow alignment cycles and significant hands-on effort. The process also introduced variability and made planning and execution less predictable, especially when calibration was needed during start-up or after maintenance.
Serial-to-parallel motor control at high frequency
The solution had to convert high-frequency serial input into synchronized, parallel motor control while maintaining signal integrity and timing. Any communication issues could translate into alignment errors, so the interface had to be robust and verifiable within the constraints of the machine environment.
Strict requirements for signal integrity, reliability and safe power-up
High-speed communication and robust start-up behavior were critical. Calculations showed inrush currents were too high, so an additional circuit was added to reduce and spread the inrush current over a longer time.
New active electronics with limited prior experience
Developing an active PCB that transforms high-frequency data into motion control was relatively new, increasing technical risk. Proving robust high-frequency communication and overall reliability required a clear validation approach and tight collaboration during testing.
Building excellence together
PDM embedded with the OEM team as a co-development partner with result responsibility. We translated requirements into functional blocks and delivered the complete electronics package, including schematic design, PCB layout and a validation approach.
Through short feedback loops with stakeholders, we reduced technical risk early and enabled a first-time-right, integration-ready active PCB.
The impact we made
The active PCB replaced a manual, sequential alignment step with a software-driven operation and was validated first-time-right.
- Automated alignment via software control
- Less hands-on work, no manual tool
- First-time-right validation, avoiding late-stage rework
- Reliable start-up through early risk mitigation
Facing Similar challenges?
PDM supports high-tech OEMs in co-developing and validating active electronics, from requirements to integration-ready hardware.
OUR APPROACH in action
We don’t just add capacity. We work as a co-development partner with end-to-end responsibility, helping engineering teams move faster while keeping quality and validation predictable.
- Co-development with result responsibility:
One integrated team and one technical owner accountable for output, progress and quality.
- End-to-end electronics development:
From requirements and functional decomposition to schematic design, PCB layout and integration support.
- Early risk reduction through validation:
Validate critial requirements early to prevent late-stage surprises.
- Design for reliable operation:
Engineer and verify robust power-up behavior and system stability as part of the design process.
- Short feedback loops with stakeholders:
Fast alignment on design choices and test results to keep delivery predictable.
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Design & Engineering
We help manufacturers accelerate complex product development through modular design, scalable architectures, and engineering excellence from concept to integration.
