Secure Prepaid Smart Meter OEM Manufacturing for Utility Markets
High-reliability prepaid smart meter OEM manufacturing with secure MCU programming and seamless token-based billing integration.
The client is a prepaid smart meter solution provider that focuses on residential utilities markets in Africa and Southeast Asia. They seek an OEM partner to produce meters that can provide tamper-proof PCBA and complete products with accurate token-based billing and more importantly has experience in encrypted MCU programming and wireless communication module integration. Their objective is to deliver a safe and scalable smart metering system that guarantees accurate billing, remote data communications, and can be implemented across different local utility infrastructures.
Project Challenges
The project needed a manufacturing partner that can provide:
• Anti-tampering and anti-cloning security MCU programming.
• Precise metering performance that meets utility-level accuracy standards
• Accurate metering performance that is utility level accurate.
• Stable Integration of keypad/token billing systems
• Meeting the IEC and RoHS requirements.
• Fast turnaround of prototypes and mass production.
MOKO’s turnkey OEM capability proved the best fit, as traditional suppliers struggled to integrate security, reliability, and scalability.
MOKO’s Turnkey Prepaid Smart Meter Manufacturing Solution
To meet the technical and quality requirements of the customer, MOKO provided a turnkey OEM manufacturing solution that involves engineering review, secure programming, assembly, and functional testing.
Engineering Support (DFM / DFA)
Optimized pad design, BOM and PCB stack-up of stable manufacturability.
Ensured electrical, RF, and structural integrity for meter assembly
Secure MCU Programming & Encryption
Implemented encrypted MCU programming with secure firmware handling
Ensuring anti-cloning and anti-tampering security in the prepaid logic.
PCBA to Final Assembly Integration
SMT with 0402/0603 passives and mixed TH assembly
Complete integration of PCBA, display modules, terminals, housing, and wiring.
Deliver fully assembled, calibrated units ready for field deployment.
Functional & Reliability Testing
Token input simulation & billing verification
Relay switching and load test
Burn-in, ESD and environmental stress test
Project Results & Client Benefits
- 99.5% first-pass yield in functional testing
- 15% reduction in costs through BOM and design optimization.
- Successfully passed IEC compliance testing at first attempt
- Secure MCU prevents firmware theft and meter cloning
- Field testing demonstrated that billing and token processing were accurate, and there were no critical issues.
- Customer accelerated time-to-market by 5 weeks
“MOKO Technology delivered a secure and reliable prepaid smart meter solution with excellent engineering and manufacturing support. We can roll out our products with confidence due to their experience in the production of electricity meters and on-time delivery.”
— CTO, Smart Meter Manufacturer
