Delivering a Production-Ready FlexCase E Variant for a Global Integrator

Challenge

One of our integrator partners was selected by a major vehicle manufacturer to deliver a production-ready control module. The integrator worked closely with the OEM to define all hardware and software requirements, but needed a partner who could handle the hardware, firmware, and production side of the program. This allowed the integrator to focus on their application layer and support the OEM directly with vehicle-level integration.

The project requirements were demanding:

• The FlexCase E platform at the time did not support PLC for EV charging, a hard requirement from the OEM.

• The application software was provided as a closed-source package, requiring a secure manufacturing process to protect the integrator’s IP.

• The OEM required that the module be manufactured in its country of origin to meet domestic content rules.

• The program had aggressive timelines — a complete cycle from kickoff to volume delivery in just 18 weeks.

• The integrator needed full support for homologation, cybersecurity requests from the OEM, and unique branding to establish their identity in the final product.

In short, the integrator needed a partner that could deliver fast, cost-controlled, and globally supported production without compromising IP security or OEM requirements.

Solution: Leveraging FlexCase E for Integrator Needs

We delivered a customized hardware variant based on our proven FlexCase E platform. Our team handled hardware design, firmware development, and production startup, enabling the integrator to focus on their application layer and OEM collaboration.

Key aspects included:

• Secure IP Handling – The integrator’s closed-source application software was securely programmed during manufacturing, ensuring full protection of their intellectual property.

• Cost Optimization – We quickly generated a reduced-BOM version of the board, and amortized NRE across the production schedule to keep costs aligned with both integrator and OEM targets.

• Custom Features – We integrated PLC for EV charging into the design, despite it not being part of the original FlexCase E platform, while still keeping project costs low.

• Global Production Support – We relocated production to a domestic contract manufacturer in the OEM’s country of origin, qualifying their processes and spinning up a new production line within weeks.

• Logistics Efficiency – By manufacturing locally, we also reduced cross-border shipments, helping the integrator avoid tariff and duty complications.

• Remote Delivery Process – Using advanced manufacturing and testing methods, we fully supported the program remotely, demonstrating that our model works seamlessly for integrators anywhere in the world.

• Direct-to-Integrator Logistics – Fully tested units shipped directly from the factory to the integrator for integration into the vehicle, reducing lead times.

• OEM-Requested Cybersecurity – We implemented additional security features to meet the OEM’s requirements without adding burden to the integrator.

• Application Acceleration – The integrator was able to leverage our model-based design tools and wider automotive ecosystem, which allowed them to accelerate application development and validation.

• Integrator Branding – We offered unique branding opportunities, giving the integrator visibility and recognition on the production units.

Technical Approach

We followed a structured process tailored for integrator-led projects:

• Requirements & Architecture – Collaborated with the integrator to map OEM-driven requirements into a production-ready FlexCase E variant.

• Rapid Prototyping & Feedback – Delivered samples to the integrator for homologation; their fast feedback on hardware changes was quickly integrated into the final design.

• Production Transition – Identified and qualified a new automotive-grade contract manufacturer in the OEM’s country of origin. Established quality standards and spun up production in record time.

• Testing & Validation – Supplied tested samples early in the process, validated against both integrator and OEM requirements.

• IP-Secure Manufacturing – Application software was programmed during production in a secure process that ensured no exposure of the integrator’s IP.

• Global Remote Support – Managed the entire project remotely, ensuring smooth collaboration despite different geographies and time zones.

Results & Impact

The project was completed on time, on budget, and delivered measurable advantages to the integrator:

• Speed – From kickoff to volume delivery in just 18 weeks, including SKU changes, sample builds, homologation, and production ramp-up.

• Cost – Reduced BOM design and amortized NRE kept overall program costs under control while meeting OEM pricing requirements.

• Flexibility – Hardware customizations like PLC for charging were added without inflating costs.

• IP Protection – Closed-source application software was securely handled during manufacturing.

• Global Execution – Production relocated to meet domestic content rules, with global remote support proving seamless for the integrator.

• Logistics – Domestic production eliminated cross-border tariffs and duty risks.

• OEM Compliance – Integrated cybersecurity features and provided homologation-ready samples that supported ASIL and regulatory requirements managed by the integrator.

• Efficiency – Direct shipment of fully tested units to the integrator streamlined their build process.

• Application Acceleration – Model-based design tools helped the integrator reduce development time and focus resources on OEM-facing work.

• Brand Recognition – Custom branding on the units gave the integrator visibility within the OEM’s supply chain.

Conclusion

In just 18 weeks, we helped our integrator partner deliver a production-ready FlexCase E variant tailored to OEM requirements. By taking responsibility for hardware, firmware, and production, we allowed the integrator to focus on their core strength: application software and OEM support.

Our ability to integrate new features like PLC, protect IP, reduce costs, relocate production globally, and execute on aggressive schedules demonstrates why integrators worldwide can rely on Audesse to bring their vehicle programs to market faster and more securely.