Case Study

Rapid Prototyping – Retractible Belt System

Customer(EU):

World’s largest automotive safety supplier.

End customer – Mercedes Benz

Challenges

Starting from Scratch – Building a completely new ECU required designing both hardware and software from the ground up.
Accelerated Development Timeline – Delivering the first working prototype in just four months created intense time pressure.
Complex Software Integration – Ensuring all software layers (MCAL, BSW, HSM, crypto stack) worked together smoothly was challenging.
Cybersecurity and Compliance – Implementing ISO 21434-compliant security features to protect the ECU against cyber threats.
Hardware-Software Coordination – Aligning hardware capabilities with software requirements to ensure full system functionality.

Solutions

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Modular Development Approach – Developed hardware and software in parallel using a structured, modular design to simplify integration.

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Agile Project Management – Used tight milestones and iterative reviews to meet the aggressive four-month initial timeline.

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Layered Software Testing – Tested MCAL, BSW, HSM, and crypto stack individually and then together to ensure smooth integration.

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Security by Design – Implemented ISO 21434 cybersecurity measures from the start, embedding crypto functions into the ECU design.

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Close Hardware-Software Alignment – Maintained continuous coordination between hardware and software teams to ensure compatibility and functional performance.

Key Impact

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Quotation nomination – Project won – Delivering the first functional ECU in just four months accelerated led to nominating the supplier of Mercedes Benz

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Improved System Reliability – Close hardware-software integration and thorough testing ensured a robust, dependable ECU.

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Enhanced Cybersecurity – Early implementation of ISO 21434 standards strengthened protection against cyber threats.

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Efficient Development Process – Modular and agile approaches streamlined workflows, reducing rework and delays.

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Better Customer Confidence – Rapid prototyping allowed stakeholders to see functional prototypes early, improving trust and decision-making.

Applied Methodology

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Modular Design Approach – Separated hardware and software into manageable modules to simplify development and integration.

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Agile and Iterative Process – Used short development cycles with regular reviews to quickly identify and fix issues.

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Layered Testing Strategy – Tested individual software layers (MCAL, BSW, HSM, crypto) before system-level integration.

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Security-First Implementation – Embedded ISO 21434-compliant cybersecurity measures from the beginning of development.

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Continuous Hardware-Software Coordination – Maintained close collaboration between hardware and software teams to ensure functional alignment.

Tasks / Responsibilities

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Board Bring up / HW-SW Integration

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MCAL Configuration

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BSW Configuration (All stacks)

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Code implementation (Embedded C)

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Crypto Stack configuration & integration

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HSM integration

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Diagnostics definition and implementation (Candela)

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RTE Configuration

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Boot manager & Bootloader integration & configuration

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CDD implemenation (SBC)

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CANoE Simulation

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Detailed Design & Testing

Toolchain / Technologies

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DaVinci Configurator

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DaVinci Developer

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Tresos

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Tasking

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AUTOSAR

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WinIdea

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CANoE

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CANdela

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IBM Doors

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CyberSecurity (ISO21434)

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Tessy

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Flash Bootloader

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UDS

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Infineon Aurix TC32X

Team composition

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1 Cyber Security expert

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1 Low level embedded developer

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2 Autosar developers

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1 Flashing expert

First Sample

B Sample

%

Customer Satisfaction

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