Case Study
Advancing Australia’s Defence Readiness with Autonomous Sensor Systems
Anduril Industries | Dust
From concept to deployment: Electronics productisation for autonomous defence and ISR systems.
Client
Anduril Industries
Industry
Defence
Application
ISR Sensor
Anduril Industries is a global leader in autonomous defence technology, developing advanced systems that integrate edge AI, autonomy and multidomain sensors.
Their mission: deliver mission-ready allied capabilities at operational speed across land, sea, air and space.
Dust Tactical Sensor Platform
Dust is a compact, low-profile tactical sensor designed for deployment in contested and denied environments.
Built for autonomous ISR, perimeter defence and persistent situational awareness, the system integrates edge computing, multi-sensor inputs and secure comms, all within strict low-SWaP constraints.
Project Summary
This project exemplifies Extel’s ability to act as a prime electronics design and delivery partner for low-SWaP, autonomous defence systems.
By delivering ruggedised, high-reliability platforms from first concept to field deployment, Extel strengthens sovereign capability and supports the mission outcomes of leading defence innovators like Anduril.
Table of Contents
Client
Anduril Industries
Industry
Defence
Application
ISR Sensor
Anduril Industries is a global leader in autonomous defence technology, developing advanced systems that integrate edge AI, autonomy and multidomain sensors.
Their mission: deliver mission-ready allied capabilities at operational speed across land, sea, air and space.
Table of Contents
Full-scope design and delivery by
Extel Technologies.
Anduril selected Extel Technologies to lead the complete productisation of the Dust Tactical Sensor from industrial design and system architecture through to prototyping, environmental validation and defence-grade manufacturing.
As prime delivery partner, Extel engineered the electronics, embedded systems, mechanical enclosures and thermal structures, while also managing NPI, DFM/DFT and certified manufacturing under sovereign conditions.
The program demonstrates Extel’s proven capability to own complex autonomous systems from concept to deployment with full traceability and repeatable quality.
SCOPE OF WORK
Extel led the full hardware development lifecycle for Dust, re-engineering the original concept into a manufacturable and ruggedised sensor system optimised for autonomous deployment.
End-to-End Engineering for Autonomous ISR Systems
- Consolidated three PCBAs into a single integrated board
- Refined system-level architecture for power integrity, RF performance and thermal control
- Redesigned cover panel to improve ruggedisation, sealing and field serviceability beyond initial industrial design
- Integrated Jetson TX2, GNSS, LoRa, radar and IR camera modules into a compact, SWaP-optimised platform
- Applied early-stage DfM and DfT to reduce NPI iteration costs and de-risk scaling
Mechanical and Environmental optimisation
- Developed passive thermal solution and gimbal-mount compatible backing plate
- Proposed anti-icing coatings and sealing improvements
- Validated mechanical and environmental performance to MIL-STD-810G, including immersion, topple, drop and thermal testing
Technology Integration and Embedded Subsystems
- Designed precision multi-output power management and custom sequencing
- Embedded microcontroller and edge AI computing hardware
- Custom MIL-DTL-38999 interconnects to support CAN, USB and Ethernet (7+ ft)
- Synchronised control of radar, IR LEDs, camera modules and battery management subsystems
NPI Acceleration and Defence-grade Manufacturing
- Executed rapid EVT and DVT prototyping with functional and environmental validation
- Manufactured medium-run production volumes at Extel’s ISO 9001 and AS9100D-certified facility
- Ensured IPC-compliant builds with full serialised traceability
- Developed custom QA protocols tailored to program-specific thresholds
- Delivered complete manufacturing documentation, FAI and engineering reports
Deployment and Fulfilment Execution
- Aligned end-to-end logistics with Anduril’s field rollout schedule
- Provided secure, compliant packaging and documentation for field deployment
- Maintained unit-level compliance records and traceability, supporting sovereign readiness and lifecycle accountability
Product Development
Industrial design
Firmware design
Electronic engineering
Mechanical engineering
Systems engineering
Quality system design
Design Transfer & Industrialisation
Design for Manufacture and Assembly (DFM/DFX)
Production engineering
Test development
Procurement management
Quality assurance
Advanced Electronics Manufacturing
Production optimisation
End-to-end traceability
Materials sourcing
Assembly, test and inspection validation
Delivery & Sustainment
Warehousing and logistics
Continuous improvement
Lifecycle and obsolescence management
Continuous improvement
Lifecycle and obsolescence management
Evaluate Extel’s Sovereign Manufacturing Capability
Assess our defence readiness for alignment with your sovereign manufacturing programs and supplier standards.
RESULTS
Rapid Product Realisation
Extel delivered the complete hardware lifecycle from detailed system architecture through to validated production within critical program timelines. Iterative EVT and DVT cycles enabled accelerated refinement while maintaining traceability and compliance.
Mission-Ready Reliability
Dust units consistently met spec across environmental, electrical and operational testing, including MIL-STD-810G validation for immersion, drop, topple and temperature. Custom QA protocols were applied to ensure system-level fidelity under field conditions.
Sovereign Capability Delivered
All engineering, manufacturing and fulfilment was executed onshore at Extel’s ISO9001 and AS9100D-certified facility. The engagement reinforces Extel’s role as a sovereign-ready partner for advanced autonomous electronics and export-class ISR hardware.
Strategic Program Continuity
Following delivery of the initial Dust platform, Extel has remained a trusted partner across Anduril’s growing portfolio of autonomous and distributed sensing systems, including variant production, system adaptations and field deployment support.
About Extel Technologies
Extel Technologies is a global leader in advanced electronics solutions committed to delivering innovative and comprehensive services to its valued customers worldwide. With a focus on excellence and customer satisfaction, Extel is at the forefront of driving innovation in the advanced electronics industry. Extel provides advanced electronic product design, manufacturing and lifecycle management to a diverse range of industries who required precision manufacturing of advanced, high-reliability products.
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