McClain Electronics Engineering

09/04/2026

Our team is developing a reliable firmware update architecture over a 1 Mbps serial interface.

The design uses buffering, CRC checks, acknowledgments, retransmission, and a dual A/B image architecture to protect against corrupted data, interrupted transfers, power loss, failed boots, and application startup failures.

New firmware is written to an inactive image slot and becomes bootable only after validation. If the update or startup process fails, the system automatically rolls back to the previous known good image.

The key lesson is that reliable firmware updating is about more than transferring data. It requires designing for failure before it happens.

Future improvements include resumable transfers, selective retransmission, secure boot, digital signatures, and encrypted firmware transport.

09/01/2026

Building reliable manufacturing test systems means solving problems at every layer.

We’re developing an end-to-end EOL test data platform connecting Red Lion Crimson runtime with SQL Server designed to overcome unreliable runtime behavior caused by oversized SQL strings.

By splitting updates across multiple tables while maintaining a consistent Dataset_ID, the system reliably manages hundreds of bit-level test fields without sacrificing traceability or usability.

The result? Real-time manufacturing data that is reliable, scalable, and easy to access from high-level readback to deep technical detail.

08/25/2026

Engineering a smarter way to test PCBA assemblies!

This custom test fixture combines motorized pogo-pin engagement, HMI control, data acquisition, custom signal routing, and integrated test equipment into one modular platform.

The modular harness architecture allows the fixture to be quickly adapted for different UUT PCBAs by swapping dedicated pogo-pin assemblies, reducing setup time and increasing test flexibility.

The rack integrates all of the required test equipment into a single platform, including:
• Automated fixture actuation for consistent board contact
• Custom signal routing and conditioning hardware
• HMI-based test control and monitoring
• Data acquisition for electrical verification
• Integrated power supply, function generator, printer, and network connectivity

From mechanical design considerations to electrical integration and software control, this system was engineered as a complete test solution that improves repeatability, reduces operator effort, and supports scalable manufacturing.

08/21/2026

Our engineering team recently designed a holdup capacitor bank to meet a client’s need for short-duration operation after unexpected power loss.

Large capacitors at the input act as energy storage, supplying the load as the voltage gradually decays. By carefully selecting the input voltage range and sizing the capacitor bank, we can achieve reliable holdup time without added system complexity.

A blocking diode at the input ensures operation whether the source fails open or short. Holdup time depends on input voltage, capacitance, load power, and the minimum operating voltage.

For example, with a 28 V input, a load operating down to 24 V, and a 1,000 µF capacitor bank, about 100 ms of holdup can be achieved for a 1 W load.

A small amount of stored energy can make a big difference when continuity matters.

08/13/2026

Getting a custom electronics test system ready for shipment takes more than putting equipment in a box.

Our team developed and implemented a protective packaging and shipment plan for a complete test system supporting four different test configurations. The shipment includes sensitive electronics, custom fixtures, rack-mounted equipment, test cables, and delicate mechanical assemblies.

The solution combines ESD shielding, padding, blocking, wrapping, labeling, and mechanical restraint to keep every component protected, organized, and secure.

The goal? A complete system that arrives undamaged, clearly identified, and ready for customer testing and operation.

07/28/2026

We're growing!

If you're passionate about solving complex engineering challenges and developing innovative solutions that make an impact, we'd love to hear from you.

Join our team and work alongside talented engineers on cutting edge projects in electronics, embedded systems, FPGA design, hardware development, and test engineering.

Ready to build what's next? Apply today and grow your career with us.

Link to application: https://www.linkedin.com/jobs/view/4442244596/

Posted 11:33:36 PM. Senior Electrical and Electronics EngineerThank you for considering McClain Electronics…See this and similar jobs on LinkedIn.

07/15/2026

Legacy systems still perform critical missions but their aging test equipment often doesn't.

We developed a modern, modular test fixture that replaces decades-old support hardware, enabling reliable testing of multiple circuit card assemblies from a single platform. Despite limited legacy documentation, our team reverse-engineered the original functionality, modernized the architecture, and improved reliability, maintainability, and test flexibility. With integration complete, the system is now entering customer acceptance testing ahead of delivery.

The attached picture is an AI-generated representation of what we created, as we cannot use the actual photo due to company rights.

07/09/2026

Complex testing doesn't have to mean complex workflows.

Our engineers are integrating a printer, power supply, function generator, touchscreen, DAQ, custom PCBA interface, and motorized pogo pin system into one automated PCBA test fixture.

By bringing everything into a single, customizable platform, we're simplifying testing, improving repeatability, and automating error logging. Making it easier for technicians to validate hardware with confidence.

Smart integration. Reliable results. Engineered for our customer's success.

07/04/2026

Happy Fourth of July!

Today we celebrate the freedoms that inspire innovation, ingenuity, and the pursuit of excellence. We're grateful for the opportunity to support our customers, strengthen American engineering, and contribute to technologies that help shape the future.

Wishing everyone a safe, fun, and memorable Independence Day with family and friends!

07/01/2026

Great engineering starts with getting the fundamentals right.

We're developing a lightweight AXI4-Lite GPIO peripheral in Verilog that delivers reliable, deterministic communication between embedded software and FPGA hardware. The challenge isn't adding features, it's creating a compact, protocol-compliant, thoroughly verified IP core that's robust, reusable, and easy to integrate.

Simple by design. Reliable by engineering.