Modernizing a Legacy: How Device Solutions Revived a Dying Design
A small firm acquired a legacy electrolysis product line from the original equipment manufacturer. This once-reliable electrolysis machine, originally designed in the 1980s, was beginning to show its age - and its cracks. With no documentation of circuit component changes or proper manufacturing and product test procedures, customers were returning units faster than the company could keep up with. Factory yields were decreasing and, without updated design files or test procedures - only aging paper schematics - there was no clear path forward.
Though the system’s “old school” discrete analog components were still technically available from multiple vendors, the lack of modern circuit design practices and test rigor had caught up with the product. The machines suffered from EMI (electromagnetic interference) and RF issues, causing instability in the field. To make matters worse, the factory test process was no longer adequate for today’s quality expectations, leading to units leaving the line that simply didn’t meet performance standards.
Our client wasn’t looking to reinvent their product, but they needed to restore its reliability, fast.
Our Solution
Device Solutions was brought in to evaluate the full system—from legacy schematics to factory floor procedures—and chart a path to recovery. Our team began with a comprehensive hardware design review, leaning on our expertise in circuit design, RF systems, and EMI reduction to get to the heart of the problem.
We made targeted recommendations to strengthen the product at three key levels:
Circuit Design Improvements – Optimized the assembly to reduce EMI and improve electrical performance, while working within the limitations of the original analog architecture.
Manufacturing Assembly Enhancements – Recommended the use of proper sockets and heatsinks for transistors, improved grounding strategies, and better component mounting to ensure long-term stability.
Factory Test Process Updates – Helped refine the test approach to catch issues earlier in the manufacturing process, improving yields and reducing costly returns.
Instead of a complete redesign, we focused on practical, high-impact changes that honored the original design while bringing it up to modern standards.
The Results
With Device Solutions' support, the client regained control over their product. Factory yields improved, customer satisfaction rebounded, and the electrolysis machine returned to the field with renewed reliability.
By bridging the gap between legacy design and modern performance expectations, we helped breathe new life into a proven product—without starting from scratch.
Have an aging product that still has value?
Don’t let legacy challenges hold you back. Device Solutions can help you modernize what matters - without losing what works. Reach out today to get your product back on track.