Examples of DDG’s Successful Engineering Projects Include:

• Custom molding and injection process for handling encapsulation of electronic cards for environmental and structural support.  Designs include electrical, mechanical, and pneumatic systems for different applications.
• Passive, surreptitious RFID duplication system – designed to show potential customers how easy it is to read RFID cards at a distance, without the owner’s knowledge.  This system was made into a small, wallet-sized device that is easily concealed.  Capabilities to read, memorize, and reproduce the credential read from another person.  (Note, the control and use of these devices must only be used with consent and prior knowledge.)
• Battery testing and analysis – Our laboratory has special test and monitoring systems to allow load and charge testing and profiling of different batteries.  Allowing for different chemistry, size, and environmental conditions to be tested.  This allows DDG to fully understand the capacity and capability of the different batteries.  DDG can monitor subject batteries, packs, and simulate a complex load profile with varying current draw requirements.  DDG has tools to analyze data for capacity verification.
• Automation testing – multiple automated testing fixtures and specific programs have been design to verify capability of systems under test.  These include repeated tests looking for random faults.  DDG can measure and analyze currents and voltages to ensure the device under test is within limits for each mode of operation.   This allows End of Line test systems used by manufacturing companies to quickly verify printed circuit functionality.  A friendly GUI Operator interface was designed so the production line operator could easily test, verify, pinpoint, and troubleshoot boards as they came of the production line before going on to the final assembly process.  These testers and application specific interfaces could record test output, information on target assemblies, and sometimes control external machines to enable stepped or cycling temperature profiles.
• Automated 3-axis machining and engraving system for use in the final production steps with encapsulated cards.  Encapsulated cards would come out with varying amounts of flashing and extra material which required trimming.    This small, table top unit was designed and built to accept a group of devices, and when started, it would step through each device, clean up the form factor, read the internal device data through wireless interface, and engrave picture and/or serial number on the device for shipment, all without operator intervention.
• 3D design and modeling of parts using SolidWorks™ – DDG engineers design and models parts for interference/fit analysis, models for injection molded components, test fixture design, and assembled housings with PCBs, mechanical attachments, and customer specific features.
• Printed circuit board design from concept, multi-card partitioning, interconnects, schematic design and documentation, bill of material, PCB layout and design.  Design tools using Cadence OrCAD™, and Altium Designer™ tools.
• Customer training, support materials, and presentations – Digital Defense has developed a strong customer support and training program that uses printed material, videos, in-person, computer modules and presentations to support and train customers.  DDG also provides Systems Integration functions to aid where customers need these services.