Case Studies
Sudtech was founded by engineers, and every project we take on starts the same way: we analyze the customer’s full system before we design anything. The three cases below all follow the same pattern — a customer who had already failed with other suppliers, a problem that required real engineering to solve, and a result that could not have come from a manufacturer who only builds to a spec sheet.
The RF Interference Problem Three Suppliers Could Not Solve
The Challenge
A major global manufacturer of alarm and security systems needed to move their power supply from an external unit into the panel enclosure. The problem: every supplier they tried caused the radio communication module to fail. The switching noise was coupling into the receive frequency band and degrading reception. Three suppliers. Three failures. The product launch was in jeopardy.
What We Did
We started by mapping the exact frequencies the communication module used — something none of the previous suppliers had done. Our engineers identified that the switching frequency harmonics of a standard power supply design land directly in the radio band. We then built a replica of the customer’s full test environment at our factory: the antenna, the PCB, the enclosure. This let us iterate on the design and measure the result in real time, without waiting weeks for samples to travel back and forth.
The Result
Radio reception with the new internal power supply was measurably better than it had been with the original external unit. The customer launched on schedule. The product went on to become the top-selling alarm panel in its category — a result that was only possible because the power supply was treated as part of the system, not as an add-on component.
A Supplier Failure, a Fixed Deadline, and How Sudtech Turned It Around in 90 Days
The Challenge
A European manufacturer of industrial weighing scales was in beta testing with a new point-of-sale model. The product could not pass electrical qualification, and the launch date was fixed: 90 days away. The root cause was a thermal printer integrated into the scale — a load that produces short, high-current spikes that most standard power supplies handle badly. The original power supply manufacturer did not understand this and had no path to a fix.
What We Did
We redesigned the power supply specifically around the thermal printer’s load profile and delivered 10 engineering samples within 35 days. To close the gap between design certification and first production shipment, we pre-purchased components for 5,000 units before the design was fully signed off — taking on the inventory risk ourselves so the customer’s timeline would not slip. The customer’s own engineer flew to our factory to work alongside our certification team and accelerate the approval process.
The Result
The scale passed qualification and shipped on the original launch date. Because we had pre-positioned the production material, the first batch was ready to ship the moment certification was complete — no delay, no expedite fees, no missed retail window. The customer has been in production with the same power supply design ever since.
What the Other Suppliers Got Wrong — and How Sudtech Fixed It in 8 Weeks
The Challenge
A telecom equipment company had tried three separate manufacturers for a custom power supply in their fiber optics platform. All three failed — but none of them ever told the customer why. The symptoms were always the same: high component cost, quality problems in production, and an engineering team that disappeared after the first sample. By the time they reached us, they had spent over a year on the problem and were not prepared to try again.
What We Did
Before we quoted anything, we ran a joint system analysis with the customer’s engineers. Within the first session we found the real problem: the original specification contained two requirements that were mutually incompatible. Every previous manufacturer had simply built to the spec without flagging it — which is why every design eventually failed. We rebuilt the spec from the ground up, replacing rare and expensive components with standard alternatives, and delivered five proof-of-concept samples within two months.
The Result
The design passed integration testing on the first attempt and is now in full mass production. Component cost came down significantly compared to the original spec, and the switch to standard parts means no single-source risk in the supply chain. A problem that had blocked the customer for over a year was resolved in under eight weeks.