Building embedded router firmware for a mission-critical satellite communications terminal
● Context
A US satellite communications company was developing a compact multi-orbit terminal for maritime, land mobile and defense applications.
The product needed to deliver reliable connectivity across satellite and hybrid satellite-cellular networks in remote and mission-critical operating environments.
To move the terminal from concept to production, the client needed a complete embedded router and networking platform designed around its specialized hardware. This required custom embedded Linux firmware, drivers for multiple hardware components, networking protocols, a bespoke software control layer and a public API. The solution also needed to meet the integration requirements of a major global satellite network provider.
Star worked with the client to prioritize the functionality required for an MVP before progressing with integration, refinement and stabilization. Over 12 months, we combined embedded software engineering, hardware integration, QA automation, DevOps, product and project management to create a production-ready firmware foundation based on an open-source project and tailored to the terminal's hardware and networking requirements.
● Impact
We helped the client transform a complex hardware concept into a functioning satellite communications product.
Within six months, Star delivered a working MVP that could be transferred to manufacturing and used for field testing. Over the following six months, we completed further hardware and network integrations, improved the firmware and stabilized the embedded router platform.
The engagement resulted in:
- Custom embedded router firmware based on an open-source foundation and designed around the terminal's specialized hardware
- Successful integration of multiple specialist hardware components, including the development and integration of required drivers
- Completion of a major satellite network partner integration
- Automated testing and continuous integration capabilities
- A stable firmware foundation for continued field validation and product development
- A tailored software control layer and public API enabling integration with external systems
● Playbook & Journey
Project scope
The engagement followed four focused phases to reduce technical risk, accelerate development and strengthen reliability.
We validated the firmware architecture, established the development environment and defined how the software would interact with the terminal’s hardware, security controls and networking requirements.
Explore our embedded software and connected device offerings
We help telecommunications, aerospace, mobility, defense and industrial technology companies design and build bespoke embedded software for complex hardware and mission-critical operating environments.
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