IoT Environmental Monitor
End-to-end hardware + firmware + web dashboard for real-time environmental sensing.
What we delivered (snapshot)
- Four-layer PCB with on-board sensors, BLE and LoRaWAN radio, and USB-C charging.
- FreeRTOS firmware with sensor fusion, low-power sleep modes, and OTA update support.
- Minimal React dashboard for real-time readings, alert thresholds, and CSV export.
The Challenge
The client needed a compact, battery-powered device to continuously monitor temperature, humidity, CO₂, and particulate matter across distributed indoor locations — all feeding into a lightweight cloud dashboard accessible by building managers.
The device had to achieve at least 30 days of battery life on a single charge while transmitting readings every 5 minutes via LoRaWAN. Enclosure requirements included IP54 ingress protection to suit plant rooms and roof-mounted installations.
No existing off-the-shelf module met the combination of sensor accuracy, radio support, and form-factor needed, making a custom PCB design essential. The firmware stack had to be maintainable by an in-house team after handover.
Constraints
Timeline
14 weeks from Blueprint Sprint to V1 prototype
Budget Band
£25k–£40k (hardware + firmware + dashboard)
Technical Constraints
- LoRaWAN + BLE dual radio on a single board
- Battery life target: ≥ 30 days at 5-minute TX intervals
- IP54-rated enclosure, wall or DIN-rail mountable
- Firmware must pass basic CE pre-scan before handover
Our Approach
- 1
Fit check & constraints clarification
Reviewed sensor accuracy requirements, radio options, and power budget. Confirmed LoRaWAN as primary and BLE for local config.
- 2
Requirements & acceptance criteria for V1
Defined sensor accuracy bands, battery life test criteria, dashboard data latency targets, and IP54 test pass/fail.
- 3
Architecture & risk register
Power budget analysis, component availability check, and risk register covering supply chain and RF certification.
- 4
Design & build across disciplines
Concurrent PCB design (4-layer), enclosure CAD (ABS + gasket), and FreeRTOS firmware development with stub dashboard.
- 5
Integration & validation
Bench testing of power consumption, sensor calibration cross-check, LoRaWAN join and uplink validation, and enclosure fit check.
- 6
Handover package
Repository, Gerbers, BOM, build instructions, dashboard deployment guide, and a 1-hour recorded handover walkthrough.
What We Delivered
- Schematic and 4-layer PCB layout (100 × 60 mm)
- Gerbers, BOM with approved alternates, and pick-and-place files
- Revision notes from two design reviews
- FreeRTOS source code repo (STM32L4)
- Build, flash, and debug instructions
- Diagnostic CLI and OTA update module documentation
- Enclosure CAD (SolidWorks + STEP)
- Assembly drawing and gasket specification
- IP54 fit-check notes and DFM recommendations
- React + Node.js web dashboard (source repo)
- REST API and LoRaWAN network server integration guide
- Admin panel for device provisioning and alert configuration
Outcome
"V1 prototype delivered on schedule. Power profiling confirmed 34 days of battery life at 5-minute intervals—exceeding the 30-day target. The client proceeded to a 20-unit pre-production build using the delivered manufacturing pack."
Handover
- Full Git repository with hardware design files, firmware, and dashboard source
- Manufacturing pack: Gerbers, BOM, assembly notes
- Runbook: setup, calibration, and OTA update procedure
- Recorded handover call covering all deliverables
Related Services
Start Your Project
Ready to build your prototype?
Tell us about your idea and we'll help you plan the fastest path to a working prototype or V1.