Satellite Modem Redesign
A satellite communications company needed their modem redesigned into a fraction of its original size without changing the BOM or doing a full re-qualification.
Working on a hardware redesign or facing obsolete component issues? Sanders RF Consulting has expert engineers who will often improve performance, cost, and size, all while removing end-of-life components. We’ve been solving RF design and product engineering challenges since 2006.
Talk to an RF engineer →The Problem
A satellite communications company needed their existing modem redesigned into a significantly smaller form factor. The original product worked well, but it was too large and heavy for their next-generation platform requirements. The BOM for major components needed to stay the same to maintain performance and avoid a full re-qualification cycle.
Our Approach
We accepted the redesign project and applied current technologies across the board. On the component side, we moved to modern part packaging with smaller footprints. For the PCB, we transitioned from traditional through-hole vias to microvia construction, which allowed tighter routing and more compact layer stackups. We replaced the cast metal shielding enclosures with stamped shields which are lighter, cheaper, and better suited to the reduced form factor. Throughout the redesign, we kept the BOM for all major functional components identical to the original, preserving the modem’s proven RF and baseband performance characteristics.
The Result
The redesigned satellite modem came in at 1/8th the volume and weight of the original product. The first prototype build was fully functional. After one cleanup pass to move two vias, the design passed all verification tests and was released. No respins, no schedule delays, no surprises.