McClain Electronics Engineering

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United States
Lakewood, CO
McClain Electronics Engineering

We do product design and development, specializing in aerospace and space applications.

06/18/2026

Our team is currently developing a high-reliability flyback converter with auxiliary isolated outputs for a customer whose critical system requirements exceed the capabilities of standard commercial solutions.

Designing for reliability often means moving beyond simple integrated power solutions and implementing discrete control architectures that provide greater flexibility, performance, and fault tolerance.

An additional challenge is managing indirectly regulated auxiliary outputs, where transformer winding ratios, load conditions, and post-regulation techniques must be carefully considered to maintain stable voltages.

By understanding the detailed behavior of the converter across all operating conditions including light-load scenarios. We're delivering a robust power solution tailored to demanding applications where reliability is paramount.

06/16/2026

Not every challenge shows up on a schematic. During first-time high-level testing of a customer test fixture, multiple tests failed unexpectedly.
By tapping into the CAN bus and analyzing the messages exchanged between the test fixture and the Unit Under Test (UUT), our engineers were able to identify and resolve critical communication issues.

The investigation uncovered discrepancies in the customer-provided documentation, requiring deep analysis of both the hardware and software interfaces. Through systematic debugging and protocol-level troubleshooting, we resolved the issues and kept the project moving forward.

This effort highlights our ability to dive into complex bus communications, integrate hardware and software systems, and deliver solutions, even when the documentation isn't perfect.

06/12/2026

As aerospace systems grow in complexity, maintaining clear traceability between requirements, testing, and validation becomes critical.

Our team recently developed a Requirements Verification Matrix (RVM) that enables a customer to track requirement coverage, verification methods, and validation progress in real time.

By linking requirements directly to testing and reporting activities, we help ensure products are ready to survive and operate in the demanding space environment.

At MEE, systems engineering and architecture are foundational to every project, helping our customers achieve successful outcomes efficiently and with confidence.

06/09/2026

Our team is currently developing the schematic capture for a Redundant Power Distribution Unit (PDU) in Altium.

A schematic can be electrically correct yet still be difficult to review and understand. That's why thoughtful organization is a key part of our design process. By following industry best practices by placing inputs on the left, outputs on the right, power rails at the top, and grounds at the bottom. We create schematics that clearly communicate circuit operation and make reviews more efficient.

Good engineering isn't just about making a design work. It's about making it easy for others to understand, verify, and maintain.

**Note that the top of the image is the original schematic and the bottom of the image is the redone version. Bottom schematic is still in progress.

06/06/2026

One of our recent projects focused on developing a robust FPGA Over-the-Air (OTA) update solution, enabling remote updates of FPGA firmware, bitstreams, and embedded software after deployment.

Unlike traditional software updates, FPGA OTA updates present unique challenges. A failed update can potentially render a device inoperable, making reliability and recovery mechanisms critical. Our team addressed several key engineering hurdles, including:

✔ Preventing device "bricking" during updates
✔ Implementing secure update authentication and delivery
✔ Managing multiple firmware and bitstream images
✔ Coordinating hardware-software interactions
✔ Developing comprehensive verification and validation processes

The result is a secure, reliable, and scalable update framework that allows deployed systems to receive enhancements, bug fixes, and feature upgrades without requiring physical access.

Projects like this showcase the complexity of FPGA-based systems and the importance of thoughtful hardware-software co-design in delivering dependable field-upgradable solutions.

06/03/2026

Not all capacitors are created equal.

Our engineering team recently helped a customer troubleshoot an FPGA performance issue that traced back to an unexpected source: the decoupling network. A component substitution maintained the same capacitance value and package size, but changing from a ceramic to a tantalum capacitor significantly altered its high-frequency performance.

Effective FPGA decoupling requires more than matching capacitance values, it demands a thorough understanding of capacitor technologies, frequency response, and power integrity requirements. By analyzing the issue and identifying the missing high-frequency bypass path, we resolved the problem with strategically placed ceramic decoupling capacitors.

This project is a great reminder that even seemingly small component changes can have a major impact on system performance. Attention to detail and deep engineering knowledge make all the difference when solving complex hardware challenges.

06/01/2026

Good engineering is often hidden in the details.

This week we're tackling a PCBA test harness design that routes six D-sub connectors to two pogo pin plates.

The challenge? Keeping everything organized while optimizing cable routing and assembly logistics. Without the harnessing being tested, we can't test the PCBAs.

A clean harness today means reliable testing tomorrow.

05/30/2026

Behind every successful satellite mission is rigorous engineering validation.

Our team is reviewing temperature data from satellite propulsion system controller thermal and TVAC (Thermal Vacuum) testing. By comparing temperature profiles across multiple test environments, we can verify performance and validate critical design assumptions.

During this analysis, we discovered a thermocouple reporting inaccurate temperature measurements. Identifying issues like this early is critical without a detailed review of the thermal data. The problem could have carried into the final flight design.

This is why engineering reviews matter. It's not just about collecting data—it's about understanding what the data reveals and using those insights to improve reliability before launch.

05/27/2026

At our company, engineering is more than just designing hardware . It’s about listening, adapting, and delivering solutions that meet our customers’ evolving needs.

We’re currently implementing board updates following a customer-requested design change, demonstrating our team’s ability to respond quickly and efficiently to new requirements.
Recently, an issue was identified with the IC being used to interface with the UUT, and our engineering team was able to resolve and implement the required change.

Our agile development process, combined with a highly skilled engineering workforce, allows us to rapidly resolve issues, integrate feedback, and keep projects moving forward without compromising quality.

Innovation thrives when strong engineering and customer collaboration work together.

05/25/2026

This Memorial Day, we pause to remember and honor the brave men and women who made the ultimate sacrifice for our freedom.

Their courage, selflessness, and dedication will never be forgotten. We are deeply grateful for those who served, those who continue to serve, and the families who carry their legacy every day.

Address

7586 W Jewell Avenue, Suite 102
Lakewood, CO
80127

Website

https://www.mcclainelectronicsengineering.com/

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