THE CHALLENGE
A leading defense client required a rugged telemetry mission computer capable of handling a high number of I/Os, USB 3.0 connectivity, and FPGA integration, all within the confined space of a missile platform.
OUR SOLUTION
A COTS COM Express (COMe) platform was selected, our team tailored it to meet the strict performance and interface demands.
THE RESULT
A small-form-factor, Atom-based mission computer, configured and modified to the strict requirements from the customer. Fully manufactured in the EU, it provides the customer with a compact, reconfigurable solution.
Built for the Impossible:
Where COTS falls short, custom engineering delivers
A defense sector client approached us at Expando with a highly specialized need: to develop a Telemetry Mission Computer that could operate reliably within the confined and rugged environment of a missile system.
The system also needed to integrate FPGA capabilities, support a high number of I/O interfaces, and crucially also include USB 3.0 support which is a challenge in itself on computers with mil connectors.
This challenge called for a solution that balanced processing performance, ruggedization, connectivity, and space efficiency. A combination rarely found off the shelf.
COTS systems often excel in one or two of these areas, but rarely all. For instance, high-I/O rugged systems tend to be bulky; compact systems often lack FPGA support or high-speed USB; and mission-critical environments like missile platforms impose strict size, shock, and thermal tolerances that most commercial hardware simply isn’t designed to meet. In short, the client needed a system that didn’t exist in the commercial marketplace, so we developed it.
“This wasn’t just about fitting electronics into a tight space, it was about enabling flexibility, performance, and mission-readiness in an environment where failure isn’t an option. Off-the-shelf simply couldn’t meet the demand. That’s where our in-house expertise made the difference.” Project Manager, Expando.
What Expando did differently
In this case, the customer specifically required USB 3.0 connectivity to interface with modern, high-speed peripherals. However, the use of circular MIL connectors, posed a major compatibility issue. These connectors are not designed for the high-frequency signaling requirements of USB 3.0, making it nearly impossible to route USB 3.0 through them without significant signal loss or instability.
To overcome this, Expando’s engineering team took a practical and reliable approach: we integrated two native USB 3.0 connectors directly into the mission computer itself, bypassing the limitations of the MIL circular connectors entirely. This allowed the customer to retain full USB 3.0 performance without compromising system integrity or ruggedization.
Our process to the modified solution
At Expando, we specialize in modifying commercial off-the-shelf (COTS) technologies to the specific needs of military applications. Leveraging our in-house embedded systems knowledge and military-grade integration experience, we embarked on a multi-step process:
- Requirement Analysis
We work closely with the client to map out all functional, environmental, and dimensional requirements. This included detailed I/O mapping, thermal conditions, shock/vibration constraints, and FPGA compatibility. - Platform Selection
We identified a suitable COM Express (COMe) COTS platform as the base, known for its modularity and performance. This platform offered a starting point with the flexibility required for further customization. - Custom Modifications
We then customize the mission computer to:- Integrate USB 3.0 support, which wasn’t native on the chosen COMe module
- Optimize I/O configuration to meet the high-connectivity demands
- Ensure FPGA interfacing capabilities for real-time signal processing
The Result
Expando delivered a small form factor mission-ready Telemetry mission computer that:
- Operates reliably within extreme missile environments
- Fit the unit into a compact, missile-compatible enclosure
- Features USB 3.0 connectivity for fast transmission of data and high I/O density
- Integrates an FPGA module, giving the customer full flexibility to configure and adapt the system to their needs.
- Utilizes an Intel Atom processor for low power and efficient processing
- Was developed and manufactured in the EU, reducing export compliance risks and delivery times
“Integrating USB 3.0, high-density I/O, and a configurable FPGA into a missile-compatible footprint pushed every limit, thermal, electrical, mechanical.
But that’s exactly the kind of challenges we’re here for.” Project Engineer, Expando
Why Expando
This project exemplifies Expando’s ability to bridge COTS flexibility with bespoke engineering, delivering powerful, compact solutions under extreme constraints. With a team of experts in the field and a strong track record in defense applications, we continue to deliver innovation where it’s needed most.
