What does Khayal Incotech do?

Khayal Incotech is a hardware product development studio. We take embedded products from idea to mass production: schematic, PCB layout, firmware (ESP32/STM32/nRF52), mechanical, certification, and DFM.

What technologies do you specialize in?

ESP32, STM32, nRF52840, BLE 5.x and BLE Mesh, LoRaWAN, KiCad, Altium, Zephyr RTOS, and FreeRTOS.

Do you work with medical devices?

Yes. Class-II wearables and clinical-grade hardware. Our founder Hamza Rehman is a biomedical engineer, and we follow the IEC 62304 software lifecycle.

Globally distributed team. We serve clients worldwide, primarily USA, EU, and APAC, through Upwork (Top Rated, 100% Job Success) and direct engagements.

Khayal Incotech · hardware × AI studio

We turn ideas into intelligent hardware that ships.

A full-stack product development studio. Electronics, PCB, firmware, mechanical, 3D printing, and apps, with AI on-device. Proof of concept to batch production, under one roof.

Start a project See our work

Electronics PCB layout Firmware AI on edge Mechanical 3D Printing App Development DFM Certification Batch Production

Bench wall · contact sheet 01

Straight off the bench.

ETL, EMC and CE certified motor control board for a smart cooker, component side — 047ETL · EMC · CE motor board

Same certified motor control board, solder side — 047ETL · EMC · CE motor board

Luckfox Lyra Pi Linux SBC with antenna and USB, powered on desk — 041Linux SBC bring-up

Round controller PCB with NFC, touch display connector and ESP32 module, 3D render — 057NFC + touch controller

Coaching device main PCB with tactile button, assembled board held in hand — 049Coaching device mainboard

Coaching device PCB back side with wireless module and connector — 049Coaching device mainboard

Assembled DC-DC buck converter board with inductor and terminals, bench photo in hand — 044DC-DC buck converter

Yellow wearable coaching device docked in its charging pod on the bench, finished product — 045Wearable coach + pod

The same wearable coaching device held in hand, single-button enclosure — 045Wearable coach + pod

Compact black IoT board with USB-C and power terminal, assembled prototype held in hand — 040Compact IoT controller

3D printed handheld timer device with touchscreen UI beside CAD enclosure render — 010Print vs. CAD, side by side

Multi-port Ethernet switch board with a row of RJ45 jacks, assembled PCB held in hand — 0548-port Ethernet switch

Ethernet switch PCB solder side with magnetics and header connectors — 0548-port Ethernet switch

Round LCD smartwatch demo showing RGB UI, wired to a motor driver on bench — 043Round-LCD UI demo

Pebble-shaped enclosure opened to show the round PCB and coin cell seated inside — 052Enclosure fit, opened up

Round wireless wearable PCB with RF module and header pins, assembled board held in hand — 051Round BLE wearable

Pebble-shaped wearable on its USB charging cable with status LED lit, held in hand — 053Charging, LED alive

Red 3D printed enclosure with perforated grille panel, exploded CAD render — 022Vented enclosure, exploded

Trusted by founders, studios, and product teams

RFRAIN swellframe HeatGo Product Labs BURL STUDIOS jackjack Mike Taggett Ahorro Energía Flexmanager

Jobs on Upwork

completed + in progress

Upwork JSS

100%

top rated · verified

Avg. reply

0-4h

working days

Shipped products

25+

across IoT, medtech, consumer

Certification · shipped at volume

Passed the lab. Then shipped 5,000+.

Compliance is designed in from the schematic and pre-scanned on our bench before a board ever sees the lab. When a board fails emissions somewhere else, we find the culprit, fix the layout, and get it back through the lab.

FCC·CE·EMC run: 5,000⁺
ETL·EMC run: 1,000⁺
Marks passed: 4

Bring us a board that has to pass →

ETL and EMC certified motor control board for a smart cooker, component side — ETL + EMC motor board

Back side of the ETL and EMC certified smart cooker motor board on the bench — ETL + EMC motor board

Anatomy

What's inside the things we ship.

Every product we touch starts as a stack — enclosure, battery, board, sensors, antenna. We design every layer, then put them together, then test that the whole thing survives drop, heat, and the field.

Top enclosure Display / UI Main PCB Battery Bottom enclosure

At a glance

What we build, ship, and stand behind.

Hardware studios talk a big game. We let the work speak. PCB layouts that pass DFM the first time, firmware that ships on schedule, products in customers' hands.

01 / Services

Hardware, firmware, PCB, AI on edge.

Twelve disciplines under one roof: schematic capture through DFM, certification, and on-device intelligence.

See all services

02 / Work

25+ shipped products. Real case studies.

BLE Mesh sensor nodes. Class-II medical wearables. Solar LoRaWAN trackers. With outcomes.

View case studies

03 / Skills

ESP32, STM32, nRF52, KiCad, Altium.

The full embedded stack: silicon, RF, firmware, RTOS, cloud. With depth, not buzzwords.

Explore the stack

04 / Clients

Top Rated on Upwork. 100% job success.

Founders and CTOs from USA, EU, and APAC have receipts. So do we.

Read reviews

05 / Team

Six engineers. No middlemen.

Led by Hamza Rehman, biomedical engineer, embedded firmware lead.

Meet the team

06 / Contact

Taking on new projects.

0-4h avg. response (working days). NDAs welcomed. Discovery calls free.

Start a project

One pipeline

From proof of concept to batch production.

Most products die in the handoff between vendors: the PCB shop blames the enclosure, the firmware contractor blames the board. We remove the handoffs. One team carries your product from proof of concept through prototype, DFM, certification, and batch production runs.

end to end

01Proof of concept
02Prototype
03Market-ready product
04Batch production

Bench shots · in the wild

Microcontrollers, boards, products — we build with.

Open PCB catalogue →

Yellow wearable coaching device with single button, finished enclosure held in hand

ETL, EMC and CE certified motor control board for a smart cooker, back side on the bench

Coaching device PCB back side with wireless module and connector, held in hand

Ethernet switch PCB with magnetics and header connectors, held at the bench

IoT device PCB inside oval enclosure, mechanical fit-check, CAD render

Wearable device PCB in transparent enclosure, mechanical assembly, 3D render

8-channel relay control board with ESP32 and screw terminals, 3D render

ESP32 IoT controller board with power terminal, assembled prototype held in hand

Handheld device enclosure section view with internal PCB and antenna, CAD render

ESP32 breadboard prototype driving a lamp, oscilloscope waveform capture on bench

Round wearable PCB with u-blox NINA module, assembled prototype held in hand

u-blox nRF52 evaluation board, assembled prototype held in hand

Wearable PCB fitted inside enclosure, mechanical assembly, SolidWorks render

Multi-port carrier board with system-on-module and USB, 3D render

Round wearable PCB with microphone and battery pads, 3D render

Motor driver PCB with TO263 regulator and JST connectors, 3D render

Round IoT sensor PCB back side with USB-C and QFN chip, 3D render

High-density BGA mainboard copper layout, bare PCB fabrication view, 3D render

7-segment display driver PCB with capacitive touch pads, 3D render

SoC mainboard with large BGA processor and memory, USB-C, 3D render

IoT device PCB inside oval enclosure base, mechanical assembly, CAD render

Access control PCB with relays, RFID reader ports and Bluetooth, 3D render

ESP32 module carrier board with screw terminals, 3D render

Wearable button PCB with tactile switches and RGB LED, 3D render

Prototype circuit soldered on green perfboard with heatsink, bench test with clips

AC-powered motor control board with EMI filter and heatsink, 3D render

AC-powered motor control board top view with mains filtering, 3D render

Particle Photon 2 IoT dev board held in hand over quick-start card

Raspberry Pi RP1 carrier board with vibration motor and display FPC, 3D render

ESP32 IoT board with GPS module, buzzer and battery terminal, 3D render

Nordic nRF52 dev kit wired to sound sensor with companion mobile app, bench test

Handheld device enclosure with status LEDs, button and speaker grille, CAD render

Cylindrical device enclosure section view showing internal PCB, CAD render

Round enclosure base with populated PCB and terminal blocks, CAD render

3D printed pole-mount bracket with fasteners, CAD render

Tall cylindrical enclosure cutaway with mechanism and control PCB, CAD render

Multi-motor driver PCB with ESP32 module and screw terminals, 3D render

Motor control PCB with large heatsink module and fan terminals, 3D render

Mains-powered controller PCB with HLK-5M05 AC-DC module and MCU, 3D render

AC-DC power supply PCB with bulk capacitors and transformer, 3D render

Red 3D printed enclosure with grille door open exposing internal PCB, CAD render

Compact black IoT board with USB-C and power terminal, assembled prototype in hand

u-blox nRF52 evaluation board held in hand at electronics bench

Verified · Upwork reviews

What clients say.

All reviews →

★★★★★

"Hamza was an incredible partner. I lacked the technical hardware depth to make effective decisions — he filled the gap end-to-end."

IoT entrepreneur

Smart Mirror · MQTT · 2026

★★★★★

"Skilled and supportive engineer. Strong knowledge in embedded systems and sensor integration. Communicates clearly, is responsive, and shows a good willingness to troubleshoot."

Sensor integration client

3D tracking · magnetic sensors · 2026

★★★★★

"Effectively created and debugged firmware for my project and ensured everything was working through physical testing. Tackled challenges along the way and delivered."

Hardware founder

STM32 LED driver · 2026

★★★★★

"Worked through some tricky Doppler radar implementation issues on an ESP32 platform. A solid engineer — would happily work with him again."

Radar startup

ESP32 · Doppler radar · 2026

★★★★★

"Delivered quality work on time with excellent communication throughout. Would definitely hire again for the next revision."

Display project lead

ESP32-S3 · BLE · 2025

★★★★★

"We expected to receive the KiCad sources and BOM to estimate our costs — Hamza prepared everything our manufacturer requested, exactly as needed."

Manufacturing client

KiCad · Gerber · BOM · 2025

★★★★★

"Stayed involved through the whole project with regular updates and progress videos. Attentive, competent — even contributed valuable feedback outside the firmware scope. Highly recommended."

Story Box founder

Noor Story Box · firmware · 2026