Silicon Labs BLE Hardware Design, PCB Layout & Prototyping

Adeate Infosoft provides Silicon Labs hardware development services including PCB design, schematic development, multilayer PCB layout, RF antenna optimization, prototype manufacturing, and embedded hardware testing for Silicon Labs BLE, Zigbee, Matter, and IoT devices. We build low power, production-ready hardware using EFR32 and BG series chipsets.

At Adequate Infosoft, we don’t simply “design PCBs for Silicon Labs.” We build hardware that really delivers on what the chip can do.

If you are looking to hire a PCB designer or an embedded systems developer for your product or need expert review and feedback for your existing PCB design and hardware board, Adeate Infosoft is the right choice.

Our certified and experienced IoT engineering team helps with PCB design, embedded firmware, hardware debugging, prototyping, and production-ready product development.

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Case Study: Smart Meter with Sub-GHz Radio

Here is a short case study on a smart electricity meter project developed for our European utility client. This real world project showcases Adeate Infosoft’s expertise in Silicon Labs embedded firmware, Sub-GHz wireless communication, low power IoT hardware and production-ready smart metering solution development for large scale connected infrastructure.

The requirements:

EFR32FG23 (Sub-GHz) for long-range data transmission
Battery-powered (10+ year lifespan)
IP54-rated enclosure
Must pass stringent CE/RED certification

The hardware challenge:

Sub-GHz radios are sensitive to board noise. The DC-DC converter (required for battery operation) was injecting switching noise into the receiver.

Our solution:

4-layer board with dedicated power plane
DC-DC inductor placed per Silicon Labs' exact specifications (AN0948.2)
Guard rings around sensitive analog traces
Extensive via stitching around the RF section

The result:

-110dBm receiver sensitivity.
12-year calculated battery life.
Passed CE/RED on the first attempt.

What We Deliver: The Complete Hardware Package

Schematic Design That Actually Follows the Reference

Silicon Labs publishes complete reference schematics. We don't just look at them. We use them as the foundation for your custom design.

The matching principles for EFR32 Series 2 are documented in application notes like AN930.2 (for 2.4GHz) and AN923.2 (for sub-GHz). We follow these. Not "mostly." Exactly.

AN0002.2 describes the power supply configurations. We do it well. For example, the layout of the DC-DC converter that most engineers screw up.

And the debug interface? Silicon Labs AN958 provides debug and programming interfaces for custom designs. Connector inserted, always. The first time your firmware doesn't flash you'll wish you had it.

Multi-Layer PCB Layout

We handle 4, 6, and 8+ layer boards. For EFR32 Series 1 devices, the recommended layer consistency is:

Top layer: RF traces and components
First inner layer: route supply and digital lines
Other inner layers: continuous GND metallization
Bottom layer: unified GND metal

The Series 2 requirements are similar, but the matching network designs are updated. We also adhere to the 20xH rule on power plane edges to minimize edge radiation. For the RF section we use continuous solid GND metallization underneath. We put many vias around coplanar lines to reduce radiation.

Controlled Impedance: 50Ω or Nothing

For RF traces longer than λ/16 at the fundamental frequency, we use 50Ω grounded coplanar waveguides. This reduces sensitivity to PCB thickness variations, reduces radiation, and minimizes coupling effects.

We specify the stack-up to your fab house. We require impedance test coupons. We verify before we assemble.

Antenna Design and Integration

Silicon Labs provides antenna simulation workbenches designed for OpenEMS to help with PCB antenna design and tuning. We use these tools. We also have experience with off-the-shelf antennas from Johanson, Pulse, and others.

We can help you select. Chip antenna, PCB trace antenna or u.FL for external. Each has trade-offs in cost, size and performance. We’ll tell you what works for your product.

From Prototype to Production: The Complete Lifecycle

Rapid Prototyping

Functional prototypes are built quickly. But “quick” does not equal careless. We produce small batches (5-25 boards) for validation. We use automated pick-and-place for assembly of SMD components. All boards we ship HAVE been tested.

Our functional testing includes:

Power-on validation (all voltage rails)
Signal integrity checks on critical nets
RF performance verification (conducted and radiated)
Firmware flashing and basic functional validation

We also follow Silicon Labs’ manufacturing test requirements that define prototype test, characterization, and low- and high-volume manufacturing phases. We don’t miss characterisation. And that's where you get into trouble before it gets expensive.

Design for Manufacturing (DFM)

Prototypes that can't be mass-produced are useless. We design for manufacturing from day one.

We optimize component selection for availability and cost. We work with assembly partners to ensure your board can be built reliably at volume. We create test fixtures for production validation.

Component Sourcing

Silicon Labs parts can have lead times. We help you navigate that.

We can identify pin-compatible alternatives where they exist. We can suggest modules (like the ZGM230S) that simplify assembly and reduce your BOM count. We work with authorized distributors to ensure you get authentic components.

One example:

The EFR32SG28B series (for Amazon Sidewalk) is available in 48-QFN and 68-QFN packages with flash configurations starting at 1024kB. We will guide you in selecting the appropriate variant for your application and supply constraints.

Hardware + Firmware: The Integration That Matters

We also develop the firmware and that is what differentiates us from pure PCB design shops.

A properly routed board is half the battle. A board that is validated with real firmware running on the real Silicon Labs SDK? It’s a product.

We collaborate with our firmware team throughout the layout process. We know which GPIOs need to be kept clean for sensitive analog functions. We know where to place the crystal for the HFRCO to start reliably. We know the power sequencing requirements that aren't obvious from the datasheet.

One example:

We've debugged boards where the RF was fine until the USB stack came up The problem ? A digital line coupling into the VDCDC feedback trace.

Our layout engineer caught it before tape-out because they knew what the firmware was going to be doing.

Silicon Labs MCU Hardware Review, PCB Design & Prototyping Development

Hire Silicon Labs MCU embedded developers from Adeate Infosoft for PCB design review, embedded firmware development, hardware debugging, RF optimization and rapid prototyping.

Our experienced IoT engineering team builds reliable, low power and production-ready connected hardware products on Silicon Labs EFR32, BG series, BLE, Zigbee, Matter, Sub-GHz platforms.

Start Your Silicon Labs Hardware Project

If you need a partner who understands silicon labs hardware – not just routing traces but building products that actually work – please contact us.

Leadership That Leads Worldwide

With a physical presence in over 15 countries and a global footprint spanning 25+ countries, we are ready to serve you anywhere. Location, language, or culture is never a barrier, because our global team can work with you in your language. Our strong international team ensures seamless collaboration across borders We have a strong tech team, highly recognized in their domains, with extensive technical expertise.

Silicon Labs BLE Hardware Design, PCB Layout & Prototyping