Integrating Notecard into a Product
When taking a smart connected product from concept to prototype to pilot to production, different hardware approaches will be appropriate at different stages. Early in the design cycle, plug-in or solder-on development modules are often best for testing, prototyping, and even low-volume production. Once a design approaches its finalized form however, engineers often switch to a custom all-in-one PCB design, readying the product for mass implementation.
This guide will introduce you to concepts that are relevant to designing Blues Notecard hardware into a given smart connected product. You'll learn how off-the-shelf Blues Notecarriers are not only the best first step, but also how best to implement Blues hardware in different production scenarios. With the proper hardware selected, your device can send data to and from the cloud with maximum reliability and minimal hassle.
noteKey Takeaways
- Start with off-the-shelf Notecarriers for prototyping and don't design custom PCBs until you've validated your concept.
- Custom PCBs make sense at volumes where engineering costs are offset by per-unit savings.
- Notecards share similar form factors and M.2 connectors, so they are designed for PCB flexibility.
- Blues provides open-source Notecarrier designs you can integrate directly into your PCB.
In This Guide
This guide covers hardware integration strategies for Blues Notecard at every stage of your product:
- Initial Product Development Stage: A progressive approach from off-the-shelf Notecarriers to custom integration.
- Choosing Between a Blues Notecarrier and a Custom PCB: Decision framework, cost analysis, and design considerations.
- PCB Design Checklist: Key items to verify before finalizing a custom PCB.
- Getting Design Help: Blues Design Review, partner network, and certification guidance.
Initial Product Development Stage
When you've chosen Blues as your wireless connectivity provider, you've chosen the fastest path to wirelessly connect your product. It also means you need a way to integrate the physical Notecard device with your system. That's where the Notecarrier comes into play.
As your smart connected product matures from concept to production, design requirements will continuously change. Even if your company has sufficient PCB expertise to build your own Notecarrier into the final product design, Blues recommends a progressive integration approach:
- Start with the easiest Notecarrier development board to prove out your concept (e.g. Notecarrier CX or Notecarrier F).
- Next, consider using a minimal Blues development board (e.g. Notecarrier X or Notecarrier XM) for testing and low-volume production.
- Then, if needed, Blues open-source designs can be integrated into your PCB for greater customization by creating a custom board based on a proven solution.
Consider that by using one of Blues' off-the-shelf Notecarrier solutions, you can test multiple concepts in hours, rather than the weeks it takes to get a custom PCB back from a fabricator!
noteIf you're brand new to Blues, a Blues Starter Kit can be an excellent all-in-one solution for initial experimentation.
Choosing Between a Blues Notecarrier and a Custom PCB
Once you have a fully functional prototype, you need to decide whether to use an off-the-shelf Notecarrier or design custom Notecard integration into your PCB. This decision framework can help:
Decision Flowchart
Ask yourself these questions in order:
- Do you have size/weight/integration constraints that a Notecarrier can't
meet?
- If yes → A custom PCB is likely required. See Getting Design Help below.
- If no → Continue to Question 2.
- Do you intend to scale this project to more than 100 devices?
- If yes → Continue to Question 3.
- If no → Consider using a Blues Notecarrier, as the cost savings you'll derive from a custom carrier are unlikely to materialize. If you’re unsure on the cut-off point, see the Key Decision Factors below.
- Do you have PCB design expertise in-house (or budget to contract it)?
- If yes → A custom PCB likely makes sense. Proceed to Key Decision Factors below.
- If no → Use a Notecarrier or see Getting Design Help below.
Key Decision Factors for Building Custom PCBs
The decision to build a custom PCB often boils down to two key questions:
- Do size/weight/integration considerations rule out a Notecarrier?
- What are the hardware costs at volume?
Size, Weight, and Integration Considerations
If your product has strict size or weight constraints that a Notecarrier can’t meet, that’s a clear signal that you’ll need a custom PCB. In practice, this is uncommon for most projects, as the X-series Notecarriers have a small footprint that fits comfortably into most designs.
Hardware integrations are a more common reason teams move to a custom PCB. For example, hand-wiring a sensor can be perfectly acceptable for an early prototype, but it can be error-prone, and can make it difficult to fit the device into a production enclosure. As integrations become more complex or mechanical constraints tighten, a custom PCB is often the cleaner and more reliable solution.
Cost at Volume
Cost at volume takes a bit more consideration, and even some guesswork, since you ultimately don't know how the product will be received. Consider a run of 1,000 devices, where the use of a Notecarrier XM would be appropriate. At a list price of $5 each as of this writing, the total cost of Notecarrier XMs would be $5000. While not a gigantic expense, it should still be minimized if possible. To save costs, engineers might consider implementing onboard carrier functionality based on an open-source Blues Notecarrier design. Let's assume this cuts BOM/assembly costs in half, to a total of $2500.
This might seem like a good thing, but an engineer has to design this functionality into the custom board, source components, set up manufacturing, and fix problems as they arise. This not only incurs engineering costs, but it can potentially delay the project by weeks or months. These non-BOM costs and risks must be seriously considered, especially when deadlines are critical. Without some other benefit (e.g. weight reduction), the theoretical $2500 cost savings becomes not worth the hassle.
However, if your predicted volume is orders of magnitude higher, the math quickly changes. Customizing a board can yield $25,000 or even $250,000 in theoretical savings, plus the value of whatever additional discounts on parts and assembly costs are available at those greater quantities, and may be well worth the effort required for a fully customized PCB. While there are pros and cons to each approach, consider the costs prior to committing to either route.
Design Considerations
To account for future Notecard designs, custom Notecarrier designs should ideally accommodate the largest Notecard dimensions of 42mm x 30mm (with an additional 5mm clear of metal around the perimeter for RF transmission if the Notecard has onboard antennas). The distance between the screw/standoff and the M.2 electrical connector is the same between all devices, so changing radio capabilities is simply a matter of securing a new Notecard in place, assuming the proper clearance is implemented. See Keep-Out Areas and Supporting Multiple Notecard Variants for more information.
warningIf you do get this point in your PCB design, make sure to read through our full Carrier Design Guide before starting your first carrier design!
Notecard XP
Finally, if you're planning to build at scale, Notecard XP offers a configurable alternative to standard Notecard models. Unlike off-the-shelf Notecards, Notecard XP allows you to customize hardware components to match your specific deployment requirements, eliminating features you don't need and optimizing for those you do.
This configurability becomes particularly valuable in volume deployments, where even small per-unit cost reductions multiply across thousands of devices. By tailoring the Notecard to your exact specifications, you can significantly reduce overall BOM costs while maintaining the reliability you expect from Notecard.
Notecard XP is available with a Minimum Order Quantity (MOQ) of 5,000, so consider this a long term option for your smart connected product. Run pilots and your initial production runs, and transition to Notecard XP when you are ready for large-scale production.
noteIf you're considering Notecard XP for your production deployment, reach out to the Blues sales team to evaluate whether it's a viable option for your project and to discuss customization possibilities.
PCB Design Checklist
Before finalizing your custom PCB design, verify you've addressed these items:
- M.2 connector footprint matches Notecard specifications
- 42mm x 30mm area reserved for Notecard
- 5mm keep-out zone around Notecard perimeter (for RF)
- Mounting hole/standoff position correct
- Antenna connector accessible (u.FL)
- I2C or UART lines routed correctly with appropriate pull-ups
- Voltage levels correct for Notecard (check datasheet for your variant)
- Power supply can handle peak current during transmission
Getting Design Help
While Blues makes it easy to enable your product to communicate with the cloud, each implementation will be different. With any new technology there is a learning curve to simply get started.
If you need assistance getting a PCB made for a new smart connected product, Blues is happy to refer you to one of our trusted partners that can take on this responsibility. If your company is proficient in PCB design, but could use specific guidance in integrating Blues products, our complimentary Blues Design Review service is available, and encouraged, for personalized help and guidance.
A Blues Design Review ensures you can utilize Notecards and Notehub to their full potential, minimizing rework across hardware and firmware. This service is available at all stages in your smart connected journey, from product ideation, to architecture guidance, to schematic and PCB layout review, and even final component selection. With Blues' expertise, your design will be well set up for success with minimal hassle and product revisions.
warningNote that while a Blues Design Review can help you avoid certain design pitfalls, and give you the best chance to avoid unacceptable RF emissions, Blues cannot guarantee compliance with certification bodies. If you do need explicit help with this challenge, Blues can also recommend partners for this task. See our Product Certification Guide to learn more.
Resources and Next Steps
Whether you're starting with an off-the-shelf Notecarrier or designing a custom PCB, Blues provides the hardware flexibility, open-source designs, and expert support to integrate Notecard into your product at any scale.
Blues Resources
- Notecard Carrier Design Guide
- Blues Notecarrier Datasheets
- Blues Open Source Notecarrier Designs
- Blues Design Review Program
Getting Help
If you have additional questions about designing a PCB for your Blues-based product:
- Post questions on the Blues Community Forum
- Contact Blues sales for enterprise-level support