Designing reliable IoT hardware is more than building a functional circuit — it’s about creating a platform that performs consistently in the field with very low maintenance, scales effortlessly, and adapts to changing needs.
At NORVI, we’ve faced and solved these challenges while developing industrial-grade IoT controllers used across manufacturing, energy, and environmental monitoring applications.
We have learned through many projects, have worked our way to make them successful.
Here are ten key challenges in IoT hardware design — and how we overcome them.
1. Understanding the Scale of Deployment
Challenge:
Many IoT projects start small — a few test devices in the lab — but scale into hundreds or thousands in the field. Designs that ignore this transition often face cost, logistics, and maintainability issues.
NORVI’s Approach:
We design every controller with scalability in mind — from the choice of components to our in-house assembly capabilities. Modular designs, standardized enclosures, and tested manufacturing processes ensure consistency at any scale. We focus how these devices are installed in the field, how often maintenance is required.
2. Selecting the Right Communication Technology
Challenge:
Choosing between Wi-Fi, Ethernet, 4G LTE, LoRaWAN, or RS-485 depends on the environment and data transmission requirements. Wrong decisions lead to connectivity issues and recurring costs.
NORVI’s Approach:
Our devices come with multiple communication options — including Wi-Fi, Ethernet, LTE, NB-IoT, and LoRaWAN — allowing integrators to select what best fits their application. Flexibility ensures reliable communication in industrial and remote deployments.
3. Managing Data Acquisition Frequency
Challenge:
Too frequent data acquisition drains power and networks; too little compromises real-time visibility. Finding balance is crucial.
NORVI’s Approach:
We enable programmable acquisition rates and event-driven data collection. Users can define reporting intervals and triggers directly through firmware, optimizing between responsiveness and power efficiency.
4. Designing for Future Expansion
Challenge:
IoT systems evolve — requiring additional I/O, sensors, or communication interfaces. Static hardware limits innovation.
NORVI’s Approach:
Every NORVI controller supports modular expansion. Our expansion series adds analog, digital, and communication interfaces on demand — protecting investments and enabling long-term adaptability.
5. Power Management for Real-World Conditions
Challenge:
Remote and off-grid installations demand ultra-efficient power management.
NORVI’s Approach:
We use power-optimized ESP32 processors and industrial-grade regulators. Our GSM series supports battery backup and deep-sleep modes for ultra-low power operation in remote monitoring applications.
6. Environmental and Mechanical Durability
Challenge:
Industrial environments expose hardware to heat, dust, vibration, and humidity — often beyond standard consumer-grade tolerances.
NORVI’s Approach:
Our enclosures and PCB designs are engineered for durability. With laser marking, industrial connectors, and reliable mounting options, NORVI controllers maintain performance even in harsh conditions.
We have made multiple designs for harsh environments, we started our business building controllers for heavy machinery. Check our projects section.
7. Balancing Cost and Quality
Challenge:
Achieving industrial reliability while keeping costs practical for large-scale deployment.
NORVI’s Approach:
Through local PCB assembly and in-house manufacturing, we optimize cost without compromising quality. Our design philosophy focuses on functionality per dollar — ensuring every component adds measurable value.
Challenge:
IoT devices are often the weakest link in network security, making hardware-level protection essential.
NORVI’s Approach:
We integrate hardware-level security and secure boot features. Our controllers support encrypted MQTT and HTTPS connections, ensuring safe communication between field devices and cloud platforms.
We keep connected with latest security requirements, and certifies our designs and products to be compliance with them.
With RED 3.3 compliance as part of our design process, NORVI devices meet the latest European Radio Equipment Directive requirements for cybersecurity and data protection — ensuring reliability and trust in every industrial application.
9. Navigating Testing and Certification
Challenge:
Compliance with EMC, CE, or RED standards can delay product release and increase costs if not planned early.
NORVI’s Approach:
We conduct internal EMI pre-compliance testing during R&D and partner with accredited labs for formal certification. This proactive approach reduces delays and ensures regulatory readiness for global markets.
10. Deployment and Maintenance in the Field
Challenge:
Improper installations and lack of diagnostics cause premature failures and high maintenance overheads.
NORVI’s Approach:
We develop our devices with field deployment in mind — offering DIN-rail mounting, clear labeling, and easy connectivity. Remote monitoring, OTA updates, and well-documented installation guides minimize downtime and simplify maintenance.
Conclusion
At NORVI, we design not just hardware, but platforms for scalable IoT solutions.
From communication flexibility to modular expansion and industrial-grade reliability, every design decision reflects our commitment to empowering system integrators and developers with dependable tools for connected innovation.