Let's build something
Available for contract FPGA design, PCBA development, mixed-signal systems, hardware V&V, and regulated-industry engineering. Medical devices, defense, and high-reliability applications.
Get in Touch20 years of production hardware across medical devices and defense — FPGA architecture, PCBA design, and the regulatory depth to deliver in environments where compliance isn't optional.
Threshold Forge Engineering is a hardware design consultancy built on 20+ years of hands-on experience across FPGA architecture, PCBA design, mixed-signal systems, and high-bandwidth video processing. From medical device platforms under 21 CFR 820 and IEC 60601-1, to defense simulation systems for military medical training, the work has always lived where precision is non-negotiable.
Every engagement draws on experience across the full product lifecycle — from architecture definition and cross-disciplinary design reviews through verification, regulatory submission, and production support on manufacturing floors in the US and Asia Pacific.
Arthroscopic endoscopy visualization · Electrosurgical platforms (coblation & resection) · Cerebral/somatic oximetry · Brain monitoring (EEG) · Military patient simulation · Tactical medicine training systems · High-bandwidth camera systems · Mixed-signal data acquisition
Production RTL targeting the Xilinx UltraScale+ ecosystem. Explicit reset strategies, clock domain crossing managed at the architecture level, and parameterized IP cores built for reuse — not throwaway prototypes.
Board-level hardware from schematic capture through layout, stackup design, and manufacturing handoff. Power distribution, high-speed signal integrity, and DFM reviews — delivering production-ready board files, not just schematics.
Bridging the analog-digital boundary — the threshold where sensor physics becomes digital data. Signal conditioning, A/D and D/A subsystem design, power supply architectures, and hardware bus integration for real-world sensor interfaces.
Self-checking, timing-aware RTL testbenches that model real-world conditions. Automated hardware test fixtures using LabView and CompactRIO for production-line incoming inspection and subsystem validation.
Hardware development under 21 CFR 820 quality system requirements and IEC 60601-1 medical electrical safety. Design history files, requirements traceability, V&V protocols, and safety certification submissions — from endoscopy visualization to electrosurgical platforms, across US and international markets.
High-bandwidth video processing for native 4K/UHD applications. MIPI CSI-2 TX/RX, 6G/12G-SDI output, AXI4-Stream datapaths — where photons become pixels become transport streams.
Two decades across medical devices, defense simulation, and high-reliability platforms. Mixed-signal data acquisition, FPGA architecture, PCBA design, verification, and production support — not narrow specialization, but the breadth to see problems whole.
Deep roots in medical device development under 21 CFR 820 design controls and IEC 60601-1 electrical safety. Hardware V&V, safety certification (CE, UL, FCC, TUV), and design transfer to manufacturing — built into how we work, not bolted on after.
Production-proven expertise across the Xilinx ecosystem — UltraScale+, Kintex-7, and Spartan families. Vivado, IP Integrator, timing closure, CDC analysis, and deep familiarity with the primitive libraries. Comfortable selecting the right silicon for the application, not forcing every problem into one family.
Engineering experience across US and Singapore teams — comfortable operating across time zones, coordinating with contract manufacturers, and supporting production ramp internationally.
Requirements review, architecture proposal, weekly deliverables, design review gates. Every engagement follows a structured signal path — from specification through implementation to validated handoff. You get working hardware and complete documentation, not open-ended billing.
Available for contract FPGA design, PCBA development, mixed-signal systems, hardware V&V, and regulated-industry engineering. Medical devices, defense, and high-reliability applications.
Get in Touch