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Our services

Full-stack engineering, from first brief to factory floor.

We don't hand off between teams. Design, hardware, firmware, and software move in parallel — under one roof, with one point of accountability.

01 ——

End-to-end product realization

One team. One contract. The entire product lifecycle.

Most hardware startups lose months — and often the plot — stitching together a mechanical firm, a PCB house, a firmware contractor, and a software agency. We eliminate that entirely. Formic Labs runs the full stack: from requirements and architecture through prototyping, validation, and manufacturing handoff. You get a single team that understands every constraint at every layer.

What we deliver
Product requirements & technical scope
System architecture & block diagrams
Hardware + software developed in parallel
Functional prototype with test rigs
DVT / EVT validation support
Manufacturing-ready files & BOM
Tools & process
KiCadAltium SolidWorksFusion 360 GitJira DFM reviewFMEA
02 ——

Hardware design

PCB to enclosure. Designed for the real world, not just the bench.

We design hardware that ships. That means every schematic is reviewed for EMI, every layout for thermal management, and every enclosure for assembly and serviceability. We've designed boards that operate in industrial environments, cold chains, and high-voltage EV charging systems — and we bring that production experience to every new project.

What we deliver
Schematic capture & review
Multi-layer PCB layout (2–12 layer)
Enclosure & mechanical design
Thermal & EMI analysis
Component selection & sourcing
Gerbers, BOM, assembly drawings
Tools & expertise
KiCadAltium Designer LTSpiceSolidWorks STM32NXP ESP32TI Power electronics
03 ——

Software & firmware

From bare-metal to backend. Everything the hardware needs to come alive.

Firmware is where hardware products succeed or fail. We write embedded code that is tight, reliable, and maintainable — optimised for the constraints of your specific microcontroller and use case. We then extend this to cloud connectivity, OTA update infrastructure, companion mobile apps, and operator dashboards. The full software stack, built to production quality.

What we deliver
Bare-metal & RTOS firmware (C/C++)
Bootloaders & OTA update systems
Device drivers & HAL integration
Cloud connectivity & backend APIs
Companion mobile apps (iOS & Android)
Operator dashboards & data pipelines
Stack
C / C++FreeRTOS ZephyrPython React NativeNode.js AWS IoTMQTT ModbusOCPP
04 ——

IoT & connected systems

Sensors, connectivity, cloud, and insight — designed as a single system.

IoT products fail when the hardware, connectivity, and cloud are designed independently. We design IoT systems holistically — the sensor node, the wireless protocol, the gateway, the data pipeline, and the dashboard are all considered together from day one. The result is a system that works reliably in the field, at scale, with data that is actually useful to the end operator.

What we deliver
Sensor node hardware design
Wireless protocol selection & integration
Gateway & edge processing systems
Secure cloud data pipelines
Real-time monitoring dashboards
Alert logic & reporting infrastructure
Protocols & platforms
BLE 5.xNFC LoRa / LoRaWANWi-Fi ZigbeeMQTT AWS IoT CoreAzure IoT Matter Time-series DB

In-house capabilities

Prototyping & fabrication — all under one roof.

We don't just design products — we build them. Our in-house lab is equipped with professional-grade tools across 3D printing, laser fabrication, PCB assembly, and CNC machining, so your prototype moves from file to physical in days, not weeks.

FDM 3D Printing · Multi-material
BambuLabs H2D
AMS MULTI-COLOR / MULTI-MATERIAL SYSTEM
Up to 16-colour prints in a single run
Multi-material: PLA, PETG, ABS, ASA, TPU, PA, PVA support
High-speed FDM with 0.05–0.35mm layer resolution
Functional enclosure mockups with living hinges and snap fits
Multi-durometer assemblies — rigid + flexible in one print
Resin SLA Printing · Large Format
Formlabs Form 4L
LARGE-FORMAT MSLA · ALL RESINS EXCL. MEDICAL GRADE
Large build volume — ideal for full-size enclosure prototypes
25 micron layer resolution for production-finish surface quality
Resin range: Standard, Tough 2000, Durable, Rigid 10K, Flexible, High Temp, Clear, Castable
Optical-clarity parts for lenses, light guides, display windows
Investment casting patterns via Castable Wax resin
SLS Nylon Printing · No Supports
Formlabs Fuse
SELECTIVE LASER SINTERING · PA12 NYLON
Support-free printing — complex geometries with no post-processing marks
Strong, isotropic PA12 nylon parts — close to injection-moulded properties
Interlocking assemblies, hinges, and moving parts printed in-place
Ideal for functional end-use prototypes and jigs
High part density per build — cost-effective batch production
Laser Cutting & Engraving
xTool P3
DIODE LASER · CUTTING + ENGRAVING
Cut: acrylic, wood, leather, cardboard, fabric, and thin plastics
Engrave: aluminium, stainless steel, anodised surfaces, ceramics, glass
Custom enclosure panels, labels, and product markings
Acrylic light guides and diffuser panels for LED applications
Precision cuts for membrane overlays and gaskets
PCB Assembly · Pick & Place
Opulo LumenPnP v4
OPEN-SOURCE SMD PICK & PLACE MACHINE
SMD component placement from 0402 upwards
Low-to-medium volume PCB assembly for prototypes and pilot runs
Eliminates manual placement errors on fine-pitch components
Compatible with standard reflow oven workflow
Rapid board bring-up for hardware iteration cycles
CNC Machining · Milling
Wegstr CNC
DESKTOP CNC MILL · 3-AXIS
Machine: wood, acrylic, PCB substrate (FR4), ABS, soft aluminium
PCB milling for rapid single-sided prototype boards
Custom brackets, mounting plates, and structural panels
Precision pockets and cutouts for enclosure assembly
Engraving and surface finishing on flat stock
Prototyping & fabrication services we offer clients
3D Printed Prototypes
Functional enclosure and mechanical prototypes across FDM, resin, and SLS processes — matched to your accuracy, material, and finish requirements.
FDM SLA resin SLS nylon
Rapid Enclosure Mockups
Appearance and fit-check models for industrial design validation, investor demos, and client presentations — before committing to tooling costs.
Multi-colour FDM Clear resin
Functional Mechanical Parts
End-use prototype parts in engineering-grade materials — snap fits, hinges, brackets, gaskets, and load-bearing components tested in real conditions.
PA12 nylon Tough resin CNC
Prototype PCB Assembly
Small-batch SMD PCB assembly for hardware bring-up and prototype validation — fast turnaround without outsourcing to a contract manufacturer.
SMD assembly 0402+ Reflow
Custom Panels & Laser Parts
Laser-cut acrylic panels, engraved metal labels, custom gaskets, membrane overlays, and light guides for product finishing and UI elements.
Laser cut Laser engrave Acrylic
Castable & Investment Patterns
Wax-resin patterns for investment casting of metal parts — enabling low-volume metal prototypes and small production runs without hard tooling.
Castable wax resin Metal casting

Why Formic Labs

Built by engineers who've shipped real products.

No handover friction

Hardware and software are designed together by the same team. No miscommunication between firmware and board design. No integration surprises late in the project.

DFM from the start

We design with manufacturing in mind from the first schematic. Every decision — component selection, PCB stack-up, enclosure tolerances — is made knowing it has to be built at scale.

Proven in the field

Our experience spans EV infrastructure, pharmaceutical cold chains, and industrial IoT — environments where hardware failure is not an option. We bring that standard to every project.

Ready to build
something real?

Tell us about your product. We'll tell you how we'd approach it.

Start a project →