Autonomous Vehicle PCB Design | Self-Driving Electronics Engineering

Autonomous vehicle PCB designs implement sensor fusion platforms, redundant compute architectures, high-bandwidth networking, and functional safety achieving ISO 26262 ASIL-D ratings supporting Level 3-5 automated driving requiring real-time processing of camera, radar, lidar data at >100GB/s throughput with <100ms latency while maintaining fail-operational capability ensuring safe operation despite single-point failures across robotaxis, autonomous trucks, and ADAS platforms demanding validated safety and reliability throughout 10-15 year operational lifetimes.

At APTPCB, we provide specialized autonomous vehicle design services implementing redundant architectures, high-speed interfaces, and safety validation with PCB conformal coating protection supporting domain controller through L5 autonomy platforms.

Achieving Fail-Operational Redundancy

Autonomous vehicles require fail-operational capability continuing safe operation despite compute platform, sensor, or network failures through redundant processing, diverse sensors, and validated degradation modes. Redundancy challenges include synchronizing parallel compute paths, managing sensor disagreements, and validating fail-operational behavior. Inadequate redundancy implementation prevents L3+ certification, creates single points of failure, or causes unsafe degradations — significantly impacting safety certification and autonomous capability.

At APTPCB, our designs implement validated redundancy achieving fail-operational capability and safety compliance.

Redundancy Implementation

Dual Compute Platforms: Independent processing paths with diverse algorithms reducing common-mode failures with special PCB manufacturing precision.
Sensor Redundancy: Overlapping coverage from cameras, radars, lidars enabling continued operation despite sensor failures.
Network Redundancy: Duplicate Ethernet networks maintaining communication despite network failures.
Power Redundancy: Independent power supplies ensuring continued operation despite electrical faults.
Degradation Management: Safe degradation modes enabling minimal risk maneuver to safe state during failures.

Safety-Critical Operation

Through redundant architecture and comprehensive validation coordinated with NPI assembly development, APTPCB enables fail-operational autonomous systems.

Implementing High-Bandwidth Sensor Networks

Autonomous vehicles process 4-12 cameras (8MP at 30-60fps), 5-10 radars, 1-5 lidars generating >100GB/s raw data requiring automotive Ethernet (1000/2500BASE-T1, 10GBASE-T1) networks, PCIe interconnects, and real-time processing. Networking challenges include deterministic latency, time synchronization, and electromagnetic compatibility. Inadequate networking causes sensor data loss, timing jitter affecting fusion, or EMI impacting sensors — significantly impacting perception quality and safe operation.

At APTPCB, our designs implement validated high-bandwidth sensor networking achieving real-time performance.

High-Speed Network Implementation

Automotive Ethernet Backbone: 1-10Gbps switched networks connecting sensors to compute platforms.
Time-Sensitive Networking: TSN protocols achieving <1ms deterministic latency for time-critical data.
PCIe Gen4/5 Interconnects: High-bandwidth compute-to-compute communication supporting sensor fusion.
Sensor Synchronization: Precision time protocol (PTP) synchronizing sensors to <100ns enabling accurate fusion.
EMC-Compliant Design: Shielding and filtering preventing EMI impacting sensor or network performance.

Through high-speed design expertise and validation coordinated with mass production scalability, APTPCB enables autonomous sensor networks.

Autonomous Vehicle PCB Design

Achieving ISO 26262 ASIL-D Compliance

L3+ autonomous systems require ASIL-D functional safety implementation through safety analysis (FMEA, FTA), architectural safety mechanisms, and validation activities demonstrating <10 FIT failure rate. ASIL-D challenges include achieving >99% diagnostic coverage, validating systematic capability, and demonstrating safety throughout development. Inadequate safety implementation prevents certification, creates liability exposure, or limits autonomous capability — significantly impacting product viability and market introduction.

At APTPCB, we support ASIL-D designs achieving highest automotive safety integrity levels.

ASIL-D Implementation

Safety Architecture

Hardware fault metrics achieving ASIL-D random hardware failure targets.
Comprehensive diagnostics detecting >99% of potential failures.
Safe-state transition enabling minimal risk maneuver during critical failures.
Freedom from interference preventing non-safety functions impacting safety.

Development Process

ISO 26262 V-model development with requirements traceability.
Safety validation activities including fault injection and degraded mode testing.
Systematic capability demonstration through controlled processes.
Independent safety assessment validating compliance.

Through ISO 26262 expertise and automotive safety experience, APTPCB enables ASIL-D autonomous systems achieving certification.

Supporting Domain Controller Integration

Autonomous domain controllers integrate compute, networking, power, and thermal management into centralized platforms requiring compact packaging, comprehensive I/O, and automotive qualification. Integration challenges include thermal management of 200-500W platforms, connector density, and automotive environmental compliance. Inadequate integration limits performance, creates reliability issues, or prevents packaging — significantly impacting system feasibility and commercial viability.

At APTPCB, we support domain controller design achieving integration and automotive compliance.

Domain Controller Implementation

High-Performance Compute: NVIDIA Drive, Qualcomm Snapdragon Ride, or Mobileye platforms with AI accelerators.
Comprehensive I/O: Automotive Ethernet, PCIe, CAN, LIN supporting diverse vehicle interfaces.
Advanced Thermal Management: Liquid cooling or high-performance heat sinks managing multi-hundred-watt dissipation.
Automotive Qualification: Extended temperature, vibration, and EMC testing per automotive requirements.
Scalable Architecture: Modular designs supporting L2+ through L5 capability across vehicle platforms.

Through domain controller expertise and automotive manufacturing coordinated with component sourcing of qualified parts, APTPCB enables next-generation autonomous vehicles.