Design to Build Process
Custom Electronics Design and Manufacturing
From initial concept to full-scale production, Control Resources, Inc. manages the entire lifecycle of custom microprocessor-based power electronic controls. Every stage of our process is handled in-house at our USA facility. Whether you need to customize one of our catalog products or develop a completely new solution, we have the expertise to deliver.
Design to Build Process
How Does Product Customization Work?
No two OEM applications are identical, and your control shouldn’t be, either. Whether you’re sourcing a proven off-the-shelf board or need something engineered from the ground up, we work with you to find the right fit for your project, your volume, and your budget. We have three options for our products: our catalog products, specials, and full on customs.
Catalog Products
Start here to see what we offer. Our catalog products are a good option if you are looking for something cost effective and ready to ship soon. We can customize these as much or as little as needed, becoming either a special or custom product.
Modified Standards or “Specials”
Sometimes a catalog board can only get you 90% of the way there. For projects with specific hardware or firmware requirements, we can modify our catalog products rather than starting from scratch.
Full Custom Design
When no catalog product fits, we build from the ground up. Full custom designs can be rooted in an existing CRI platform or developed as something entirely new, depending on what your application demands.
Technical Discovery
Our engineers collaborate directly with your team to define the precise specifications required for your application. This phase focuses on mapping your required inputs to the specific performance logic of the control. We specialize in translating complex input variables—whether signaled via pressure, temperature, analog, or digital and serial protocols—into reliable, repeatable control logic.
Common control inputs and protocols we support:
- Analog: 0-10V, 4-20mA
- Sensor-Based: Temperature, Pressure, Humidity
- Digital & Serial: MODBUS, I2C, UART, SPI
Specification & Quotation
We present a clear, strategic path forward based on your technical requirements. Whether that involves a ready-to-ship catalog product, a modified standard, or fully custom electronic controls, we provide a quotation that balances performance with your commercial goals.
Rapid Prototyping
When you are ready to move forward, we bridge the gap between design and physical reality. We prioritize putting a functional, high-quality working model in your hands quickly for testing and validation, moving your project from specification to the bench as efficiently as possible.
Review and Validation
Once the prototype is in your hands, the floor is yours to test and validate. We encourage rigorous evaluation to ensure the control performs exactly as intended. If you identify a need for changes, we move fast—our design and build teams work side-by-side, allowing for seamless communication and immediate technical adjustments.
Massachusetts Based Manufacturing & Testing
To ensure total quality control and short lead times, all of our products are produced and tested in our Massachusetts facility.
Lifecycle Support
We don’t just ship and disappear. From conception to full-scale production runs, we provide hands-on support for the life of your product.
What Are The Steps for a Custom Project?
What Are Some Popular Applications?
Thermal management & Fan Control
For HVAC manufacturers, fan OEMs, exhaust hood builders, and heat pump producers looking for precise, reliable control over airflow and thermal behavior.
Here are some popular uses:
Air Comfort Control
Combustion Control
Ventilation & Exhaust Control
Controlling Fans to be Certain CFMs
Device Cooling
For medical devices, telecom enclosures, data center equipment, and defense electronics that require precise cooling control.
Here are some popular uses:
Device Thermal Regulation
Acoustic Noise Reduction
Fan Synchronization
Fan Failure Monitoring
Motor Speed Control
For fractional horsepower BLDC, brushed DC, EC, or PSC motors that need custom speed control.
Here are some popular uses:
Power Tools
Pumps
Value Actuator
Not in Any of These Groups? We Can Help
Some applications don’t fit a category. Odd voltage requirements, unusual sensor inputs, control logic that doesn’t map to anything in a standard catalog; if you’ve already ruled out off-the-shelf options and know you need something unique, that’s exactly the kind of project we take on.
Why OEMs Choose Custom Solutions
You Have a Specific Application Need
Catalog boards are built for broad compatibility, which usually means compromises: over-featured, oversized, or simply not calibrated to your exact I/O requirements.
You Need Modifications to Meet Performance Demands
Off-the-shelf control solutions often lack the precise flexibility required to optimize specialized systems. When standard modulation and algorithms fall short of your exact efficiency, spacing, or environmental constraints, a tailored approach is essential to achieve peak performance.
You Are Looking to Reduce Costs and Increase Operational Efficiency
Reduce expenses and simplify assembly by consolidating “piecemeal” components into a single integrated control. By replacing multiple off-the-shelf parts with one custom board, you eliminate excess wiring, reduce points of failure, and streamline your bill of materials (BOM).
Design to Build Case Studies
Case Studies
The best way to understand what the Design-to-Build process looks like in practice is to see it in action. From early-stage custom control designs to long-running production programs with companies like Honeywell, Nokia, and Lockheed Martin, our work spans industries and decades. Here are a few examples of what we’ve built and who we’ve built it with.
Reviews From Our Peers and Customers
Insights
Engineering Resources
Engineering insights, product updates, and resources to help with your next project.
One Board, 70+ Integrations: How Heatco and CRI Consolidated Five+ Controls into One
CRI Design Guide: Custom Fan Speed Controls & Alarm Integration
CRI Design Guide: Fractional HP VFDs
CRI Design Guide: Brushless Motor Controllers
Temperature Conversion Chart
CRI SmartFan® Applications
SmartFan® Installation Tips
I2C Communications Tips
Device Cooling Design Tips
Thermal Design for ATCA Systems: Compliance, Interfaces, and Fan Tray Architecture
SmartFan Integration: The Case for Adaptive Cooling
AC Motor Compatibility
Custom AC Motor Control with Programmable Keypad in NEMA 4X Enclosure
Fan Controller Technology and Motor Efficiency
How CRI Reduced This Boiler Controller Cost by nearly 50% via Board Integration
Custom Electronic Design & Manufacturing: Advanced Irrigation Controller
Raphael 4040 Delivers Selective No-Mask Conformal Coating
Control Resources Introduces LabStrobe II with Rechargeable Power Source
Control Resources adds 4 New Sensor options
Control Resources Deemed Essential by Customers and the Commonwealth During Corona Pandemic
SmartFan® Multi SD DC Fan Controller, NOW FIELD PROGRAMMABLE
CRI Adds Nimbus II Triac AC Fan Speed Controller
Cirrus 6 and Vortex DC Fan Control – CE Certification Update
CRI Introduces New Aurora Motor Controller
CRI Introduces Universal Brushless DC Motor Controller
Work With Us
If your current control is holding your product back, or you’re starting from scratch and need a partner who’ll see it through, let’s dig into the details together. Reach out to the team and we’ll take it from there.
