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Box Build

From brief to 15km range – designing and manufacturing a drone communication box end-to-end

15km
Operating range achieved
Multi
Protocol support — RC, telemetry, video, payload
HW+SW
Hardware and software designed in-house
Mass
Production — manufactured and tested at scale
The Challenge

A drone company with a specific communications requirement and no off-the-shelf answer.

Modern drone operations particularly in defence, surveillance, agriculture, and industrial inspection demand communication systems that go well beyond basic radio control. A serious drone deployment needs reliable bidirectional communication across multiple data streams simultaneously: radio control for flight, telemetry for system health and position data, video downlink from the camera payload, and payload-specific data protocols for specialised equipment.
The client needed a ground-side communication box capable of handling all of these streams simultaneously at ranges up to 15km. No standard off-the-shelf product met the full requirement. The combination of protocols, range, and integration into their specific drone platform meant this had to be designed from the ground up.
They came to us with the requirement and we delivered the product from hardware architecture through to tested, mass-produced units.

Our approach
01

System architecture & hardware design

Complete hardware architecture defined for the Base Com Box – RF front-end design for 15km range, multi-protocol modem integration, power management, and enclosure requirements. PCB designed for the full hardware implementation.

02

Embedded software development

Firmware developed for the communication box – protocol stack implementation for ELRS, Crossfire, telemetry, video, and payload data streams, with real-time management of simultaneous communication links and RF channel coordination to minimise interference.

03

Protocol integration & validation

Each communication protocol integrated and validated independently before full system integration confirming range performance, latency, and data integrity for RC, telemetry, video, and payload streams under real operating conditions.

04

Box build — enclosure, integration & testing

The complete Base Com Box assembled – PCB, RF components, antennas, connectors, and enclosure integrated into a finished, field-ready unit. Every unit functionally tested across all protocol streams before despatch.

05

Mass production

Following successful validation, the same team that designed the product transitioned it to mass production maintaining the quality, test coverage, and protocol performance of the prototype across every production unit.

Protocol scope
Four communication streams. One integrated box.
ELRS & Crossfire (CRSF)
ExpressLRS and TBS Crossfire protocols integrated for long-range, low-latency radio control providing reliable command link to the drone at 15km operating range.
Bidirectional telemetry
Real-time flight data — altitude, speed, GPS position, battery state, and system health transmitted back to the ground station for operator awareness and mission management.
Video downlink
Live video transmission from the drone's camera payload to the ground station integrated into the same communication box with appropriate RF management to avoid interference between streams.
Payload data protocols
Communication support for specialised payload equipment enabling data exchange between payload sensors or instruments and the ground station alongside the core RC and telemetry links.
The Outcome

A drone company with a specific 15km-range communication requirement and no in-house electronics manufacturing capability received a complete, production-ready Base Com Box designed from scratch by our engineering team, built and tested at our facility, and scaled to mass production without a change of partner. RC, telemetry, video, and payload protocol support delivered in a single integrated ground-side unit.

15km
Range achieved
4
Protocol types integrated
HW+SW
Full design in-house
Mass
Production delivered

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    Why this matters

    Drone technology in India is moving fast from hobbyist platforms to serious commercial, agricultural, and defence applications. The electronics behind these systems – communication boxes, flight controller PCBs, payload integration hardware need to be designed for real-world operating conditions, not just lab validation.

    This programme shows what we bring to emerging technology companies: not just manufacturing, but the complete engineering capability to take a product from requirement to production-ready without splitting the programme across multiple vendors. One team, from first schematic to mass-produced unit.

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