Overview
When a large U.S.-based defense technology company needed a software-driven test system to support mission-critical hardware, they turned to Triple Crown to take full ownership of the project. Their internal team lacked the bandwidth to execute the work within a tight timeline and needed a trusted partner who could step in quickly and deliver results. Having successfully partnered with Triple Crown on previous projects, the client’s technical lead trusted our team to take on the workload and ensure execution from start to finish.
Challenge
The objective was to develop an automated PCB validation station for printed circuit boards used in the Department of Defense mission systems. Triple Crown deployed a cross-functional team to design and implement the software test harness, spanning embedded firmware, Python-based test automation, and FPGA development. Our engineers updated the FPGA/SoC design to support required interfaces (SPI, I²C, Ethernet) and host connectivity (USB/Ethernet as applicable), while developing embedded APIs and automated test scripts to validate board functionality. The end-goal was to create a robust, repeatable test system designed to support rapid validation of mission-critical hardware.
Project Goals
The client’s goal was to ensure their printed circuit boards could be validated quickly, consistently, and with complete confidence before being used in mission-critical systems. They needed a test system that could automatically verify foundational board conditions such as power rails, clock presence, and reset behavior, as well as validate communication interfaces and connectivity. The system also needed to confirm proper FPGA boot configuration and execution, with clear pass or fail criteria and repeatable automated test sequences that could be easily run by operators. Success was defined by a simple outcome: the software reliably tested their boards and produced immediate, trustworthy results.
Scope of Work
Triple Crown handled the full scope of work across FPGA development, embedded firmware, and software. Our team developed the FPGA design, implemented PetaLinux-based embedded Linux software stack, and wrote Python code to support automated testing within the test system. By combining hardware, firmware, and software expertise, we delivered a fully integrated solution that met the client’s testing requirements.
The project was completed over a two-month timeline, aligned to a strict delivery schedule tied to incoming test boards. Triple Crown worked closely with the client throughout the engagement, holding weekly status meetings and maintaining ongoing communication multiple times per week. This consistent collaboration allowed the team to quickly address questions, adapt to feedback, and keep the project on track through delivery.
Solution
The client faced a strict deadline tied to the arrival of their test boards, requiring the test system to be fully functional before their boards arrived. Triple Crown met this deadline, delivering the solution on time and enabling immediate testing upon board arrival. We delivered a fully integrated software-driven test system that the client continues to use for their internal hardware programs. The system allows their team to quickly and consistently validate printed circuit boards, supporting faster decision-making around board readiness.
By completing the project within a two-month timeline and delivering a rapid turnaround, Triple Crown helped the client accelerate their testing process and reduce delays in their hardware development cycle.