RF Welder Product Refresh
Industrial
Project details
Helped a customer refresh their product design and maintain market leadership by balancing size, weight, power, and cost (SWaP-C) parameters.

Specialized Electronic Design, Systems Integration, and Test Engineering
TCB Engineers is a professional engineering practice registered in Arizona and Colorado, offering specialized services in electronic design, systems integration, and test engineering. With over twenty years of experience, the practice designs and validates systems for harsh environments, specializing in RF engineering, analog circuit design, automated test systems (ATE/STE), and Certified LabVIEW Architect consulting. It works with diverse clients across aerospace, defense, medical, and industrial sectors to solve complex technical challenges from concept to commissioning.
Certified LabVIEW Architect
Thomas W. MillerPrincipal Engineer & Founder
Adopts an interdisciplinary, requirements-based approach that spans the entire development lifecycle, from defining customer needs and framing solution paths during the Concept of Operations (ConOps) phase to design verification and validation.
Vetting product ideas, removing design uncertainties, framing achievable solution paths, flowing down critical-to-quality (CTQ) requirements, and performing Pugh concept selection.
Converting physical phenomena to digital information, incorporating embedded data acquisition, and optimizing size, weight, power, and cost (SWaP-C) constraints.
Develops automated test systems (ATE) and special test equipment (STE) ranging from static measurements to real-time hardware-in-the-loop (HIL) systems for validation, verification, and manufacturing floor applications.
Architecting cost-effective, high-reliability automated test and special test equipment utilizing multi-disciplinary skills across electrical, mechanical, and software engineering.
Certified LabVIEW Architect (CLA) services including turn-key application development, legacy software modification, and embedded system programming.
Leveraging the TestStand sequencing engine to develop robust, automated manufacturing test flows and data acquisition sequences.
Designing, building, and deploying durable, maintainable industrial control systems, SCADA, and UL-508 industrial control panels.
Applies electromagnetic, magnetic, and high-frequency circuit design principles to transmission lines, antennas, stripline circuits, material characterization, and packaging.
Designing lumped and distributed component models, bounding performance envelopes against manufacturing variation, and developing stripline circuits.
Validating high-frequency circuits and microwave systems, specializing in electromagnetic field, wave, and magnetic interactions.
Evaluating high-speed electromagnetic wave interactions in complex electronic designs to eliminate interference and timing issues.
Designs electronic circuits and systems with built-in electromagnetic compatibility and safety, covering both front-end and back-end verification processes.
Designing robust analog circuits, signal conditioning networks, and power subsystems optimized for harsh environments.
Mitigating noise, electromagnetic interference, and electrostatic discharge risks by integrating protective design practices early.
Integrating regulatory design criteria from concept through verification, leveraging relationships with testing laboratories to screen designs early.
Aerospace · Defense · Government · Healthcare · Medical Devices · Industrial · Manufacturing · Telecommunications · Renewable Energy · Power Generation · Research Facilities · Consumer Products
Industrial
Helped a customer refresh their product design and maintain market leadership by balancing size, weight, power, and cost (SWaP-C) parameters.
Aerospace
Engaged in a formal systems design process to develop a high-reliability radar safety controller optimized for harsh environments.
Manufacturing
Developed an accessible, automated test system that enabled a customer to adopt advanced manufacturing capabilities without high complexity and cost.
Research Facilities · Client: Colorado State University
Designed a sophisticated, SWaP-optimized, high-reliability cavity ring-down spectroscopy (CRDS) laser sensor with an IP-67 rating to serve as a UAV payload for academic research.