Single Board Computers (SBCs) are compact, fully integrated computing systems that are built on a one circuit board. They play an essential role in modern embedded applications, ranging from industrial automation and robotics to IoT gateways and medical devices.

As industries evolve, the demand for customisable SBCs has grown. Companies increasingly require boards tailored to specific hardware interfaces, environmental conditions, and performance requirements. Standardised SBC solutions often cannot meet these specialised needs, making flexible and scalable design essential.

Electronics Manufacturing Services (EMS) providers like PCI play an essential role in delivering this level of adaptability. By combining engineering expertise, PCBA manufacturing, rapid prototyping, and full lifecycle support, PCI enables clients to create high-performance SBCs that are precisely aligned with their application requirements.

The Shift from Standard to Custom SBCs

Standard SBCs allow for convenience and rapid deployment. However, they have limitations in terms of scalability, interface options, and other features critical for performance in specialised environments.

On the other hand, custom-engineered SBCs are designed to meet precise requirements for performance, connectivity, and durability, tailored to the unique demands of specific applications.

Businesses are increasingly turning to custom SBCs for several reasons:

• Integration with proprietary systems

Custom boards can support specialised interfaces, sensors, or protocols that standard boards cannot.

• Compliance with strict industry standards

Industries like medical, industrial automation, and transportation require boards that meet rigorous safety, EMI/EMC, and environmental standards.

• Cost optimisation for volume production

Tailored designs can reduce unnecessary components and simplify assembly, lowering total lifecycle costs.

Some examples of custom SBC applications are:

Core Design Considerations in Custom SBC Development

Developing a custom SBC requires careful engineering to ensure the board performs reliably under its intended conditions. Key considerations include:

1. Processor and Architecture Selection

Choosing the right CPU is critical to balance processing power, energy efficiency, and compatibility with other devices operating within the same network.

For instance, IoT gateways may prioritise low-power processors for continuous operation over the long term, while industrial automation SBCs might require high-performance processors to handle complex control algorithms.

2. Input/Output (I/O) Interface Configuration

The type and number of input/output interfaces, including USB, serial ports, GPIO, or expansion connectors, must align with the device's application.

Customisation ensures that the SBC can seamlessly integrate with sensors, actuators, displays, and other elements without unnecessary hardware complexity.

3. Thermal Design

As SBCs are so compact, they can experience heat buildup that impacts performance and lifespan.

Engineers must plan for mitigating methods such as heat sinks, thermal pads, and airflow strategies to dissipate heat effectively, ensuring reliable operation even in challenging industrial or outdoor environments.

4. Form Factor and Mechanical Design

The physical layout of the SBC is crucial in space-restricted environments. Custom boards may require unconventional shapes, different mounting points, or reinforced areas to fit machinery, vehicles, or handheld devices without compromising connectivity or component placement.

5. Longevity and Component Lifecycle

Maintenance and servicing are essential for custom SBCs. By selecting components with long-term availability, manufacturers ensure that boards can be repaired or produced consistently over years, which is critical for industries like transportation and industrial IoT, where devices have long lifecycles.

By addressing these factors early in the design stage, EMS providers like PCI help clients create SBCs that are not only high-performing but also matched to the specific needs of their application.

How Electronics Manufacturing Partners Enable SBC Customisation

Electronics manufacturing services (EMS) providers like PCI play a crucial role in transforming standard SBCs into fully customised solutions. Their integrated expertise ensures that each board meets unique client requirements while remaining manufacturable at scale.

1. Collaborative Engineering

At PCI, we engage early with clients through joint design planning sessions, ensuring alignment on elements like hardware architecture, component selection, I/O configuration, and mechanical layout to the specific application.

This collaboration ensures functional requirements, regulatory standards, and environmental considerations are fully addressed before prototyping begins.

PCI also employs principles including Design for Manufacturing (DFM) and New Product Introduction (NPI). DFM ensures that a product is designed to be as efficient and cost-effective as possible to manufacture, while still maintaining the highest standards in quality.

Meanwhile, NPI acts as a bridge between the design and manufacturing phases for a new product, such as a custom SBC, which is thoroughly evaluated, prototyped, and validated before moving into full-scale manufacturing.

2. Rapid Prototyping

PCI's in-house prototyping capabilities enable quick iteration and testing of various designs and component layouts for custom SBCs. This allows clients to validate the design's performance, ensure the compatibility of components and materials, and identify potential issues early.

By minimising the number of redesigns and adjustments required at the prototype phase, full-scale production of the SBC can be carried out smoothly and at considerably less expense.

3. Advanced PCBA Manufacturing

SBCs require precise and highly technical assembly for printed circuit boards (PCBs), including techniques for high-density interconnects, multilayer PCBs, controlled impedance traces, and other delicate components.

By leveraging PCB assembly and manufacturing expertise from EMS providers like PCI, clients can ensure signal integrity, thermal stability, and reliability for high-speed, specialised SBC applications in industrial automation, IoT gateways, and more.

4. Scalable Production

From low-volume speciality boards to high-volume deployments, EMS partners provide flexible production planning that adapts to different stages of a product's lifecycle. A capable EMS provider ensures that the transition from pilot runs to full-scale manufacturing is seamless, with consistent process control and testing protocols.

For industries like industrial IoT or transportation, where device rollouts can expand rapidly across regions, this scalability ensures that clients can ramp up production scale confidently without compromising reliability or delivery timelines.

5. Supply Chain Optimisation

Supply chain strength is critical for custom SBCs because these boards rely on specialised materials and components, many of which have long lead times or limited suppliers.

EMS providers manage material sourcing, component lifecycle, and risk analysis to ensure the long-term viability of the design. By planning contingencies for unavailable components, securing long-term agreements with suppliers , and providing early warnings, EMS partners minimise disruptions and cost fluctuations.

For clients, this means smoother production and a more predictable path from prototype to ongoing manufacturing.

PCI adopts a proactive and tech-driven approach to supply chain management. With industry-leading platforms like Kinaxis and Silicon Expert, we are able to optimise our planning and sourcing capabilities for custom SBC engineering.

The Future of Custom SBC Manufacturing

The next generation of custom Single Board Computers (SBCs) will be shaped by several powerful technology trends redefining what's possible at the edge

• Modular architectures and SOM-based designs

SBCs are moving toward increasingly modular designs, where key components, such as processors, storage, and I/O, can be swapped or upgraded without redesigning the entire board. This will make it simpler to scale performance and customise features for different purposes.

• Integration of AI and edge computing

Future SBCs will integrate dedicated AI accelerators, NPUs, and GPU-capable modules to run models locally with low latency. This shift supports real-time decision-making without relying on cloud connectivity, which is ideal for sectors like manufacturing, healthcare, and smart cities.

• Enhanced energy efficiency and miniaturisation

Manufacturers increasingly demand devices that deliver high performance while consuming less power. Designing for energy efficiency also supports sustainability goals and reduces long-term operational costs. Meanwhile, miniaturisation is especially important for wearables, smart devices, and portable industrial devices.

To meet these evolving requirements, PCI is already investing in advanced engineering expertise, AI-ready design support, and specialised manufacturing processes for future-ready, optimised SBCs.

Build Confidently with PCI's Custom SBC Expertise

As the demand for smarter and more efficient devices continues to grow, EMS providers like PCI play a crucial role in bridging the gap between innovative custom SBC design and high-reliability manufacturing.

By combining deep engineering expertise with in-depth production processes, PCI helps companies turn complex concepts into robust, scalable products ready for real-world deployment.

With capabilities spanning precision PCB assembly, rapid prototyping, modular design support, and long-term lifecycle management, PCI stands as a trusted partner for organisations building next-generation custom SBCs.

Partner with PCI to bring your next custom SBC design to market with confidence, quality, and speed.