Ground Control Station for Uncrewed Surface Vehicles (USVs)

Overview

RDS Partnered with a defence marine manufacturer to design and produce a portable ground control station for a new fleet of uncrewed surface vehicles (USVs). The system was required to integrate proprietary safety systems within a rugged, all-in-one PC platform capable of reliable operation in demanding marine and defence environments. RDS delivered a fully industrialised hardware solution, supporting rapid development from concept through to scalable production.

Challenge & Objectives

The customer required a control station that could:

• Integrate proprietary safety and control systems within a single, portable unit
• Incorporate a large 21.5" projected capacitive (PCAP) touchscreen
• Support a high-performance single board computer (SBC)
• Accommodate complex networking and communications requirements
• Include IP-rated human interface devices (HID) suitable for harsh environments
• Remain lightweight and portable without compromising ruggedness

The solution needed to balance performance, durability and portability, while meeting stringent defence and marine operational demands.

Design & Development

RDS engineered a fully industrialised all-in-one control station, using the customer's proof-of-concept unit as a reference point. The design process focused on upgrading all critical components to ensure long-term reliability in harsh operating conditions.

Key elements of the design included:

• 21.5" PCAP touchscreen for intuitive, high visibility control
• High-performance SBC to support mission-critical applications
• Robust internal architecture to manage complex networking requirements
• IP-rated HID devices for reliable operation in marine environments
• Carbon fibre construction to reduce weight while maintaining strength
• Compact, portable form factor optimised for deployment flexibility

Materials, thermal management and mechanical design were carefully considered to deliver a solution suitable for both defence and marine use, without unnecessary size or weight penalties.

Production & Deployment

RDS delivered functional prototypes in under 12 weeks from the initial engagement. An iterative design approach enabled rapid refinement, ensuring the platform was optimised for manufacturability and scalability. This allowed the customer to move quickly from prototype to production readiness.

Outcome & Impact

The rapid transition from concept to production enabled the customer to be first to market in a highly competitive USV class. The successful deployment of the ground control station helped secure large-volume orders and positioned the customer strongly within the defence marine sector.

Key Takeaways

• Portable, rugged all-in-one ground control station for USVs
• 21.5" PCAP touchscreen with high-performance SBC
• Integration of proprietary safety and control systems
• Lightweight carbon fibre construction for improved portability
• Rapid prototyping and scalable production capability

RDS delivers end-to-end hardware design and manufacturing solutions for defence and marine applications, supporting customers from early concept through to volume production.