Recovering value from legacy systems
Across multiple sectors from defence to advanced manufacturing, there remains a significant reliance on embedded electronic systems that were designed decades ago. These units whether control modules, sensors, or boards are often critical to operations, yet the manufacturers have long since discontinued support. Documentation is incomplete or missing altogether, diagnostics are limited, and spare parts have become difficult or impossible to source.
While some businesses attempt to source refurbished units or pursue complete system upgrades, these options can be commercially impractical, incompatible with current infrastructure, or lead to lengthy downtime. In such situations, reverse engineering offers a strategic alternative: one that preserves existing capability, reduces the risk of system failure, and allows teams to better understand and manage the modules they depend on.
EES Solutions supports organisations facing these challenges through a structured, consultancy-led reverse engineering process. Our work begins with an assessment of the failed or unsupported unit, identifying all available data points. From here, we map the hardware and firmware environment, document interfaces, and create the foundation needed for a safe, validated reproduction of the component or system.
A structured engineering method
Reverse engineering is not simply a teardown exercise. Our approach is governed by traceable documentation, methodical testing, and industry-recognised best practice. We employ high-resolution imaging, X-ray scans of multilayer boards, firmware analysis, and functional simulations to reconstruct and interpret the behaviour of the original module. This technical understanding enables accurate specification recovery, even when source materials are missing.
In practice, this might involve replicating a damaged control unit to exact specification or identifying opportunities to redesign it for improved robustness and maintainability. In one example, our engineers worked on a fleet-critical module where diagnostics were unavailable and the manufacturer no longer existed. We conducted a full specification discovery and revalidated the recreated unit using a bespoke test rig, returning the system to service and saving the client from multi-million-pound replacement costs.
These projects are often not about modernisation for its own sake. They are about protecting business continuity, extending operational life, and ensuring control over systems that still serve a purpose. For engineering leaders managing complex asset portfolios, reverse engineering allows a new level of insight and confidence, particularly when faced with compliance updates or the challenge of systems integration.
EES Solutions provides not just the technical skillset but also the structured documentation and advisory support to guide decisions. We integrate this work with systems thinking, lifecycle assessments, and ongoing operability planning. Whether for high-integrity applications in defence, safety-critical roles in transportation, or production-sensitive industrial settings, reverse engineering is a means to take back control.
If your team is currently managing ageing electronics with no upgrade path or supplier support, reverse engineering may be the most practical next step to ensure future reliability. We bring clarity, structure, and a deep technical foundation to help teams do exactly that.