Free e-book: Discover the world of AIoT
E-book: Discover the world of AIoT

Industrial IoT devices, engineered for the factory floor.

Stop settling for off-the-shelf solutions that fail under pressure. We design, build, and deploy custom IoT devices that transform legacy machines into smart assets, ensuring resilience, efficiency, and safety.
needCode IoT

We work with Industry Leaders

The challenges of industrial transformation

Modernizing a factory requires more than just connecting devices. It demands a solution engineered to overcome specific industrial hurdles.

Integration with legacy systems

Connecting aging machinery with existing wired protocols (e.g., Modbus, CAN, RS485) to modern IoT platforms is a significant and costly challenge. Retrofitting off-the-shelf hardware often leads to hidden costs and integration failures.

Unpredictable downtime

Unplanned machine downtime is a major driver of lost productivity and revenue. A lack of real-time monitoring and predictive analytics leaves businesses reactive, not proactive, to potential equipment failures.

Harsh environment resilience

Industrial devices must withstand extreme temperatures, vibrations, dust, and electrical interference. Standard consumer-grade hardware is not designed for such demanding conditions, leading to frequent failures and maintenance issues.

Security and compliance

Industrial systems are critical infrastructure. Ensuring cybersecurity consistent with guidelines like NIS2 and meeting regulatory compliance (e.g., ATEX/IECEx) is a non-negotiable requirement. Non-compliant solutions can expose vulnerabilities and delay market entry.

Our solution

We provide a complete, modular solution that addresses these industrial challenges head-on. Our engineering approach turns these hurdles into a competitive advantage.

01

Seamless legacy integration

Our Protocol Translation Gateway is a bidirectional software layer that converts industrial protocols (Modbus RTU/TCP, CAN) into modern IoT standards (MQTT, REST). This enables a unified view of all your assets, regardless of their age or communication standard.

02

Engineered for resilience

We deliver Modular Enclosure & Power Options that are IP-rated and ruggedized for demanding industrial environments. Our Power Continuity & Failover Module ensures systems continue operating or gracefully shut down during outages, preventing data corruption and maintaining uptime in critical infrastructure.

03

Predictive maintenance at the edge

Our solutions combine our Motion & Orientation Module for vibration analysis and our Edge Data Processing Engine to perform real-time anomaly detection directly on the device. This empowers you to predict failures and schedule maintenance before a disaster strikes, reducing bandwidth costs and ensuring immediate decision-making.

04

Security and compliance by design

Our devices are built with a solid security baseline, including encrypted data channels and secure OTA updates. We ensure our hardware and firmware choices align with CE, RED, NIS2, and ISO principles, giving you a significant head start on certification.

Go from concept to connected factory, faster.

We specialize in integrating legacy protocols with modern technology, ensuring seamless communication and robust performance. Partner with our experts to build an IoT solution that works in the most demanding industrial environments.
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Where our industrial IoT devices fit

Our modular approach allows us to deliver optimized solutions across multiple industrial applications, solving common problems with uncommon speed and precision.

Machine health & predictive maintenance

We deploy gateways that integrate with industrial equipment, capturing data from vibration sensors, temperature probes, and current monitors. This enables predictive maintenance programs and reduces unplanned downtime by combining multiple data streams into a single alert.
  • Vibration analysis
    Our Motion & Orientation Module is used to analyze vibrations, helping to predict maintenance needs and prevent unplanned downtime.
  • Temperature monitoring
    We integrate high-precision temperature probes to monitor critical machine components, ensuring they operate within safe ranges and enabling proactive maintenance.
  • Anomaly detection
    Our Edge Data Processing Engine performs real-time anomaly detection on-device, filtering raw data before sending it to the cloud and ensuring that critical warnings are never missed.

Energy management

Our solutions provide real-time energy monitoring, allowing you to identify waste, optimize loads, and comply with energy efficiency regulations. The Utility & Energy Measurement Module delivers flexible scaling for industrial ranges and provides configurable alerts for power anomalies.
  • Power quality data
    Our solutions measure voltage, current, and power factor, providing a comprehensive view of electrical health and helping to identify inefficiencies.
  • Cost optimization
    By providing visibility into energy consumption per machine or production line, we enable data-driven decisions for cost allocation and operational efficiency.
  • Compliance ready
    Our systems help manufacturers comply with energy efficiency regulations by continuously logging detailed consumption profiles for audits and reporting.

Worker safety & asset tracking

We create Hybrid Safety Tags that use BLE and UWB for precise positioning, enabling real-time monitoring of worker location and activity in hazardous zones. The system can trigger alerts when a worker enters a restricted area or detects falls or inactivity.
  • Real-time geofencing
    We monitor worker presence within digitally defined zones (e.g., hazardous areas or production cells) and trigger automated actions, such as alarms or shutting down machinery, when a boundary is crossed.
  • Fall and inactivity detection
    Our tags are equipped with onboard accelerometers and gyroscopes, which enable sensor fusion for accurate fall detection and motion analysis.
  • Tool and component tracking
    We use our solutions to precisely locate tools and components on the factory floor, preventing Foreign Object Debris (FOD) incidents in highly regulated environments like aerospace MRO (Maintenance, Repair, and Overhaul).

Supply chain & logistics

Our devices enable real-time tracking of components, tools, and vehicles within the factory, optimizing material flow and inventory management. Our UWB RTLS solutions are also used in aerospace MRO to precisely locate tools and prevent Foreign Object Debris (FOD) incidents.
  • Material flow optimization
    We track assets in real time to provide insights into material flow, helping to identify bottlenecks and optimize production line efficiency.
  • Inventory management
    Our solutions provide end-to-end visibility of components and tools, minimizing search time and reducing loss.
  • Vehicle management
    We track the location and movement of vehicles like forklifts within the factory, which helps optimize their routes and manage traffic.

What we bring to your project

We do not just provide products; we architect complete digital transformation. Our partnership is built on three key stages that ensure your industrial IoT vision is realized with precision and expertise.

01

Architecting your IoT blueprint

We begin by mapping your operational needs to a complete technology stack.
  • Feasibility analysis
    We conduct a deep dive into your operational environment, from legacy machines to existing infrastructure, to define the optimal IIoT strategy. We help you navigate complex decisions, from selecting the right communication protocols to ensuring compliance with regulations like ATEX/IECEx.
  • Design and prototyping
    We utilize our library of proven building blocks to rapidly design and prototype a working proof of concept (PoC). This allows us to validate your IIoT solution's core functionality in a controlled environment, minimizing upfront risk and accelerating the path to an MVP.

02

Engineering the solution

We deliver a complete solution tailored to your needs, whether it's a single component or a full, end-to-end system.
  • Custom hardware development
    We design and engineer custom IoT devices that are ruggedized for industrial environments, ensuring they are not only robust but also perfectly suited to your specific use case.
  • Software intelligence
    We build the core software that powers your IIoT ecosystem. This includes the Multi-Sensor Fusion Engine for complex event detection and the Local Automation Rules Engine for instant, on-device responses.
  • Unified integration
    We develop the necessary API gateways and integration layers to seamlessly connect your new IIoT platform with your existing enterprise systems—such as MES, ERP, and safety management software.

03

Scale and continuous optimization

Our support extends beyond the product launch. We provide the tools and expertise to ensure your solution remains secure, reliable, and continuously optimized.
  • Operational support
    We provide a full suite of tools for remote diagnostics, field support, and secure OTA (Over-the-Air) updates, ensuring that your system remains up-to-date and reliable.
  • Data for continuous improvement
    We empower you to use the gathered data to continuously optimize safety protocols, identify high-risk areas, and improve overall operational efficiency.
  • Scalable deployment
    Our proven methodologies and a comprehensive Deployment Orchestration Toolkit ensure that your solution can be scaled seamlessly from a pilot project to a full-scale industrial rollout.

Case studies

Read more in our E-books

Testimonials

“I think the key takeaway from needCode is their ability to adapt and understand the customer's requirements. That took away probably a large portion of what could have been a lot of development time and expense for both companies.”
Bob Folkestad
Bob Folkestad
President at Creative Werks
“One aspect that truly sets needCode apart is its profound expertise in firmware development. Their proficiency in various programming languages, embedded systems and hardware architecture is truly impressive. When faced with difficult problems, their strong problem-solving skills and analytical mindset shine through, allowing them to overcome obstacles with remarkable ease.”
avatar Semeh Sarhan
Semeh Sarhan
CEO at Xtrava
“I worked with needCode while leading the NWTN-Berlin team in 2018. A big chunk for our FW development has been outsourced to them and they had proven to iterate very quickly, following specs and deliver on time. It was great working with them. I recommend working with needCode’s team on any Embedded SW development.”
avatar Marco Salvioli Mariani
Marco Salvioli Mariani
CTO at NWTN Berlin GmbH
“needCode Team proved to be one of the best engineers I have ever met. The part I like the most about the team is the more difficult an obstacle seems to be, the more motivated they were to find a solution and a way forward.”
A Testimonial picture
Szymon Słupnik
CTO at Silvair
“needCode is an outstanding partner. Their quick follow-up, scalability, and extensive professional network set them apart. Their expertise in wireless technologies has been valuable, supporting us from low-level drivers to architecture discussions.”
avatar Tim Allemeersch
Tim Allemeersch
Director at Qorvo, Inc.
“needCode did a great job improving the firmware of the Vai Kai connected toys and developing new features, surpassing our expectations multiple times. I would definitely recommend hiring Bartek and needCode for the embedded software projects!”
avatar Matas Petrikas
Matas Petrikas
CEO & Co-founder
at Vai Kai UG

Partnerships:

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Bartek Kling
Bartek Kling / CEO
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Manufacturing

Modern manufacturing machines are typically equipped with IoT sensors that capture performance data. AIoT technology analyzes this sensor data, and based on vibration patterns, the AI predicts the machine's behavior and recommends actions to maintain optimal performance. This approach is highly effective for predictive maintenance, promoting safer working environments, continuous operation, longer equipment lifespan, and less downtime. Additionally, AIoT enhances quality control on production lines.

For example, Sentinel, a monitoring system used in pharmaceutical production by IMA Pharma, employs AI to evaluate sensor data along the production line. The AI detects and improves underperforming components, ensuring efficient machine operation and maintaining high standards in drug manufacturing.

Logistics & supply chain

IoT devices - from fleet vehicles and autonomous warehouse robots to scanners and beacons - generate large amounts of data in this industry. When combined with AI, this data can be leveraged for tracking, analytics, predictive maintenance, autonomous driving, and more, offering greater visibility into logistics operations and enhancing vendor partnerships.

Example: Amazon employs over 750,000 autonomous mobile robots to assist warehouse staff with heavy lifting, delivery, and package handling tasks. Other examples include AI-powered IoT devices such as cameras, RFID sensors, and beacons that help monitor goods' movement and track products within warehouses and during transportation. AI algorithms can also estimate arrival times and forecast delays by analyzing traffic conditions.

Retail

IoT sensors monitor movement and customer flow within a building, while AI algorithms analyze this data to offer insights into traffic patterns and product preferences. This information enhances understanding of customer behavior, helps prevent stockouts, and improves customer analytics to drive sales. Furthermore, AIoT enables retailers to deliver personalized shopping experiences by leveraging geographical data and individual shopping preferences.

For instance, IoT sensors track movement and customer flow, and AI algorithms process this information to reveal insights into traffic patterns and product preferences. This ultimately leads to better customer understanding, stockout prevention, and enhanced sales analytics.

Agriculture

Recent research by Continental reveals that over 27% of surveyed farmers utilize drones for aerial land analysis. These devices capture images of crops as they are and transmit them to a dashboard for further assessment. However, AI can enhance this process even further.

For example, AIoT-powered drones can photograph crops at various growth stages, assess plant health, detect diseases, and recommend optimal harvesting strategies to maximize yield. Additionally, these drones can be employed for targeted crop treatments, irrigation monitoring and management, soil health analysis, and more.

Smart Cities

Smart cities represent another domain where AIoT applications can enhance citizens' well-being, facilitate urban infrastructure planning, and guide future city development. In addition to traffic management, IoT devices equipped with AI can monitor energy consumption patterns, forecast demand fluctuations, and dynamically optimize energy distribution. AI-powered surveillance cameras and sensors can identify suspicious activities, monitor crowd density, and alert authorities to potential security threats in real-time, improving public safety and security.

For example, an AIoT solution has been implemented in Barcelona to manage water and energy sustainably. The city has installed IoT sensors across its water supply system to gather water pressure, flow rate, and quality data. AI algorithms analyze this information to identify leaks and optimize water usage. Similarly, smart grids have been introduced to leverage AI to predict demand and distribute energy efficiently, minimizing waste and emissions. As a result, these initiatives have enabled the city to reduce water waste by 25%, increase renewable energy usage by 17%, and lower greenhouse gas emissions by 19%.

Healthcare

Integrating AI and IoT in healthcare enables hospitals to deliver remote patient care more efficiently while reducing the burden on facilities. Additionally, AI can be used in clinical trials to preprocess data collected from sensors across extensive target and control groups.

For example, intelligent wearable technologies enable doctors to monitor patients remotely. In real-time, sensors collect vital signs such as heart rate, blood pressure, and glucose levels. AI algorithms then analyze this data, assisting doctors in detecting issues early, developing personalized treatment plans, and enhancing patient outcomes.

Smart Homes

The smart home ecosystem encompasses smart thermostats, locks, security cameras, energy management systems, heating, lighting, and entertainment systems. AI algorithms analyze data from these devices to deliver context-specific recommendations tailored to each user. This enables homeowners to use utilities more efficiently, create a personalized living space, and achieve sustainability goals.

For example, LifeSmart offers a comprehensive suite of AI-powered IoT tools for smart homes, connecting new and existing intelligent appliances and allowing customers to manage them via their smartphones. Additionally, they provide an AI builder framework for deploying AI on smart devices, edge gateways, and the cloud, enabling AI algorithms to process data and user behavior autonomously.

Maintenance (Post-Release Support)

When your product is successfully launched and available on the market we provide ongoing support and maintenance services to ensure your product remains competitive and reliable. This includes prompt resolution of any reported issues through bug fixes and updates.

We continuously enhance product features based on user feedback and market insights, optimizing performance and user experience.

Our team monitors product performance metrics to identify areas for improvement and proactively addresses potential issues. This phase aims to sustain product competitiveness, ensure customer satisfaction, and support long-term success in the market.

Commercialization (From MVP to Product

Our software team focuses on completing the full product feature range, enhancing the user interface and experience, and handling all corner cases. We prepare product software across the whole lifecycle by providing all necessary procedures, such as manufacturing support and firmware upgrade.

We also finalize the product's hardware design to ensure robustness, scalability and cost-effectiveness.

This includes rigorous testing procedures to validate product performance, reliability, and security. We manage all necessary certifications and regulatory compliance requirements to ensure the product meets industry standards and legal obligations.

By the end of this phase, your product is fully prepared for mass production and commercial deployment, with all documentation and certifications in place.

Prototyping (From POC to MVP)

Our development team focuses on implementing core product features and use cases to create a functional Minimum Viable Product (MVP). We advance to refining the hardware design, moving from initial concepts to detailed PCB design allowing us to assemble first prototypes. Updated documentation from the Design phase ensures alignment with current project status. A basic test framework is established to conduct preliminary validation tests.

This prepares the product for real-world demonstrations to stakeholders, customers, and potential investors.

This phase is critical for validating market readiness and functionality before proceeding to full-scale production.

Design (From Idea to POC)

We meticulously select the optimal technology stack and hardware components based on your smart product idea with detailed use cases and feature requirements (Market Requirements Document / Business Requirements Document). Our team conducts thorough assessments of costs, performance metrics, power consumption, and resource requirements.

Deliverables include a comprehensive Product Requirements Document (PRD), detailed Software Architecture plans, an Initial Test Plan outlining validation strategies, Regulatory Compliance Analysis to ensure adherence to relevant standards, and a Proof of Concept (POC) prototype implemented on breakout boards.

This phase aims to validate the technical feasibility of your concept and establish a solid foundation for further development.

If you lack a validated idea and MRD/BRD, consider utilizing our IoT Strategic Roadmap service to gain insights into target markets, user needs, and desired functionality. Having a structured plan in the form of an IoT Strategic Roadmap before development begins is crucial to mitigate complications in subsequent product development phases.