Beating the Chip Shortage: How One Smart FPGA Strategy Kept Production on Track

In semiconductor and industrial manufacturing, long component lead times can bring innovation and production to a halt.

When a global industrial manufacturer faced a critical shortage of an older FPGA used in a key product line, they needed a partner who could move quickly and think long-term. They turned to Boston Engineering—and found the solution they needed.

Read more below.

The focus and discipline of DFX is a powerful tool if used as part of a broader strategic approach to developing product/process differentiation, and a sustainable advantage against competition. Involve Design for X in Strategy. Once your team has determined the focus of your strategy, place the focus of design on developing competitive advantage. 

At Boston Engineering, DFX is a core part of creating values during our product development process. We focus on several key DFX areas that align with our expertise:

• Design for Manufacturability (DFM)
• Design for Assembly (DFA)
• Design for Cost (DFC)
• Design for Testability (DFT)
• Design for Reliability (DFR)
• Design for Serviceability/Maintainability (DFS)
• Design for Usability (DFU)
• Design for Modularity (DFMo)

Learn more about Design for X (DFX) at Boston engineering: Boston Engineering Design for X

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The Challenge: No Stock, Long Delays, and No Room for Error

The manufacturer was relying on an outdated field programmable gate array (FPGA)—a component that had become increasingly hard to source, with long lead times and unpredictable availability. The risk? Delays in production, rising costs, and the threat of having to redesign their circuit boards to accommodate newer parts.

What they needed was a way to:

• Quickly replace the unavailable FPGA without altering the PCB.

• Ensure identical performance across different versions.

• Support future component flexibility to avoid similar issues down the road.

Boston Engineering’s Approach: Pin-Compatible, Code-Ready Solutions

Boston Engineering applied a smart, scalable approach that avoided a costly PCB redesign while securing future flexibility for the client’s hardware platform.

Here’s how they did it:

• Sourced multiple compatible FPGAs – Researched the market to identify drop-in replacements with the same pinout and footprint, eliminating the need for physical board changes.
• Custom code development – Built and validated FPGA code for each identified chip version, ensuring that timing and performance matched the original.
• Comprehensive support for production – Delivered a set of build files for each FPGA option, enabling the client to seamlessly switch between versions depending on availability.

This strategy not only solved the immediate lead time issue—it also gave the client a resilient, future-ready platform for continued production.

Interested in providing your product development team with DFX skills? Learn More about our Applied DFX process and development workshops.

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The Impact: Immediate Relief and Long-Term Flexibility

Boston Engineering’s FPGA solution delivered tangible benefits that went far beyond short-term sourcing:

Lead Time Problem Solved – The client could continue production without delays or redesigns.

No PCB Modifications Required – Thanks to pin-compatible replacements, no time or cost was spent reworking hardware.

Multi-Version Build Support – The client received fully verified build files for multiple FPGA versions, enabling supply chain flexibility moving forward.

Future-Proof Product Design – By building options into the system, Boston Engineering helped the client safeguard against future component shortages.

Designing for Resilience in Semiconductor Manufacturing

This case illustrates why today’s engineering solutions must go beyond solving short-term problems—they must also prepare systems for tomorrow’s uncertainties. Boston Engineering’s methodical and forward-looking approach allowed this global manufacturer to keep moving today and stay ready for what’s next.

Dealing with component shortages or obsolescence?

Boston Engineering specializes in building smart, adaptable solutions for semiconductor and industrial systems. Whether you need drop-in replacements, embedded system redesigns, or full product support, we’re ready to help you future-proof your technology.

New eBook Available Now! 

"Leveling Up Existing Products through DFX" 

-Download Insights from a DFX Subject Matter Expert- 

Developing successful new products from scratch is challenging enough, but what about improving on existing designs? 

In this eBook, we’ll dive into the real-world experiences of DFX subject matter expert John DePiano, exploring the common areas where existing product owners excel, as well as the key opportunities where targeted DFX support can drive major improvements.

 Understanding the Importance of a DFX approach

Applying Design for X (DFX) methodologies upfront in product development optimizes the entire lifecycle by improving manufacturability, testability, reliability, usability, and other critical characteristics. This avoids costly redesigns later on, facilitates high-quality products that satisfy customers, reduces manufacturing and service costs, and supports flexibility through modularity and platforms. The holistic perspective of DFX drives efficient, cost-effective delivery of successful products that provide competitive advantage. Investing in DFX early pays dividends across the entire product lifespan.

Do you offer training on DFX for engineering teams?

Education is critical to effectively implement DFX principles. We provide training tailored to your engineers’ roles and product lines. This includes overall DFX methodology, deep dives into specific disciplines like design for reliability or manufacturability, and practical application workshops. Our hands-on approach combines real-world examples and case studies with tutorials on leading DFX software tools. The goal is building organizational DFX expertise and establishing repeatable processes that endure beyond individual projects. Investing in DFX knowledge pays dividends across your entire product portfolio. 

Ready to Begin your next DFX Project? 

Impossible Challenge? Try Us. 

Selecting a partner to help you complete your design project is a valuable option to reduce project duration and save money.    

The Boston Engineering product development system encompasses DFX to ensure a smooth product launch and success in the marketplace.  Boston Engineering has DFX knowledge and experience to address aspects and values of a product such as manufacturability, test, reliability, safety, serviceability, cost, and compliance with industry standards and government regulations.

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