Project Overview
A leading Department of Defense (DoD) client needed a high-performance, deployable Edge Compute solution to enhance their C5ISR (Command, Control, Communications, Computers, Combat Systems, Intelligence, Surveillance, and Reconnaissance) capabilities. They required a compact platform capable of processing real-time sensor data in field, enabling advanced situational awareness and faster decision-making in challenging battlefield environments. The project demanded a full turn-key development cycle, from initial hardware design to final testing and validation.
Our Solution
Triple Crown delivered a full turn-key solution built to meet the DoD’s high standards for performance and reliability. The team included an Electrical Engineer Technical Program Manager, two schematic capture experts, and two layout engineers. From initial design to hardware bring-up and testing, they ensured every system component was designed for real-time edge processing in harsh field environments. Leveraging extensive experience in high-speed hardware design and ruggedized systems, Triple Crown developed a robust Edge Compute solution that strengthened the client’s C5ISR architecture and enhanced operational performance. Key components of the team’s solution included:
- Hardware Design and Architecture
- Custom FMC PCB: Designed to interface with a Xilinx Kintex-7 FPGA, this board handles high-speed video sensor inputs and preprocessing tasks.
- Carrier Board: Integrated the NVIDIA Orin SOM, enabling advanced software-based recognition algorithms, with eMMC/SSD flash for reliable storage.
- High-Speed Interfaces: Incorporated LVDS, PCIe, USB 3.2, and DisplayPort for robust data transfer and connectivity.
- Signal Integrity: Maintained through meticulous routing, differential pair design, and thermal stippling to ensure consistent performance in harsh environments.
- Power Management: Custom power supplies designed from scratch to meet precise power estimation requirements, ensuring efficiency and reliability.
- Manufacturability: Applied stiffening techniques to enhance durability and streamline production.
- FPGA and SOM Integration
- The Xilinx Kintex-7 FPGA was selected for its ability to process high-bandwidth sensor data in real time, critical for the C5ISR system’s video input requirements.
- The NVIDIA Orin SOM was integrated to run sophisticated recognition software, leveraging AI and computational capabilities to deliver actionable intelligence.
- Seamless interfacing between the FPGA and SOM ensured efficient data handoff and optimized overall system performance.
- Development Process
- Schematic Capture and Layout: Completed for both the FMC and carrier boards, adhering to high-speed design principles.
- Thermal and Mechanical Design: Incorporated thermal stippling and ruggedization to withstand extreme operational conditions.
- Prototyping and Testing: Began in May 2025 at Triple Crown’s state-of-the-art hardware lab in Mountain View, CA, with full PCBA bring-up and validation to ensure compliance with DoD standards.
Our Results and Impact
Triple Crown successfully delivered a compact, high-performance Edge Compute system built for challenging operational scenarios. The team resolved complex hardware issues involving:
- High-speed I/O, signal integrity, and interfaces like PCIe and USB 3.2 to ensure fast, reliable performance.
- Power and thermal systems to keep the hardware running smoothly in a small, ruggedized design.
Thanks to a streamlined process and close collaboration with the client, Triple Crown met the client’s schedule, moving from concept to completion between October 2024 and April 2025.
With proven expertise in hardware solutions, real-time processing, and mission-critical delivery, Triple Crown has demonstrated its value as a trusted partner for this advanced Edge Compute solution. Triple Crown’s full-service capabilities, from design to validation, combined with a deep understanding of DoD requirements, enabled a successful outcome for this mission-critical project. As battlefield demands evolve, Triple Crown remains committed to delivering scalable, reliable platforms that strengthen decision-making and advance the future of defense technology.