In the railway sector, safety isn’t just a requirement—it’s the foundation of reliable operations. Every system, every component, and every innovation must align with the strictest industry standards to ensure efficiency, durability, and, above all, security. This is where Elemaster Group’s International Design Centers (IDC) come into play. As the R&D division of the Group, the IDC specialises in safety engineering, pushing the boundaries of railway technology to create solutions that not only meet but exceed the industry’s rigorous requirements.
R&D: the engine behind innovation
At the heart of this research and development effort is Eletech, Elemaster’s Italian engineering division, which plays a pivotal role in railway product development. Operating in accordance with ISO 22163:2023 standards, Eletech provides a full suite of R&D services designed to anticipate industry challenges and set new benchmarks in safety and efficiency.
Eletech manages the entire product development cycle, from concept and hardware-software integration to mechanical design and conformity testing. This end-to-end approach ensures optimal performance, reliability, and compliance. Moreover, it guarantees that the Intellectual Property of every project remains with the Customer, along with all technical documentation, including Gerber files, 3D mechanical CAD models, and source code.
One of the key strengths of Eletech’s R&D capabilities is its expertise in Electronic Design and System on Module (SoM). By developing custom PCB schematics and modular SoM platforms, the company accelerates the prototyping and integration process, reducing design risks and ensuring superior product quality.
Bringing IoT to the railway sector
The integration of IoT technology is a game-changer for railway operations. By incorporating big data management, machine learning, predictive maintenance, and telemetry, Eletech enables real-time monitoring of railway systems, reducing downtime and preventing failures before they occur. This data-driven approach enhances operational efficiency and system longevity, allowing railway operators to stay ahead of potential issues.
Testing and validation: the foundation of quality
No product reaches the market without undergoing a rigorous series of tests. Eletech’s in-house compliance laboratory, accredited under ISO/IEC 17025:2017, plays a critical role in this process. It conducts electromagnetic compatibility (EMC), insulation, climatic, vibration, and shock tests, ensuring that every component can withstand the harsh mechanical and environmental conditions of railway operations.
With the ability to rapidly prototype and industrialise new products, Eletech helps railway manufacturers maintain flexibility in an industry where speed and adaptability are crucial to staying competitive.
Building for the future: industrialisation and testing
Beyond innovation, manufacturability is key. Eletech integrates Design for Manufacturing (DFM), Design for Assembly (DFA), and Design for Testability (DFT) methodologies early in the product development phase, ensuring that railway systems are not just high-performing but also efficient to produce, assemble, and maintain.
A crucial part of this process is the development of test benches for production testing, including ICT (In-Circuit Testing), Flying Probe, ATE (Automatic Test Equipment), Burn-in, and Functional Test Equipment (FCT). To further optimise testing, Eletech has developed ELETEST, a proprietary functional test platform designed to reduce implementation costs and accelerate equipment validation.
The key role of Safety Integrity Level (SIL)
In railway engineering, Safety Integrity Level (SIL) is non-negotiable. Defined by IEC 61508, SIL determines the risk reduction measures needed to prevent failures that could lead to catastrophic consequences—be it human injury, environmental damage, or severe financial loss.
Eletech has introduced SIL-Flex, a groundbreaking methodology that streamlines the development of SIL-compliant systems. This platform integrates pre-developed and pre-tested input/output interfaces, reducing design risks while significantly cutting down development time.
By supporting safety levels from SIL0 to SIL4, SIL-Flex enables engineers to create railway solutions that are both scalable and adaptable to future regulatory requirements, ensuring long-term reliability and compliance.
Driving the future of railway innovation
At the core of Eletech’s success is its state-of-the-art laboratory, which allows for full control over the testing and validation process. This ensures that railway products not only meet but exceed industry standards, accelerating the certification process while maintaining complete oversight of product quality and performance.
Through ongoing investments in artificial intelligence, predictive maintenance, and integrated IoT solutions, Eletech is redefining how railway systems operate. By enabling railway operators to predict failures, optimise maintenance, and enhance overall efficiency, the company is laying the groundwork for a safer, smarter, and more reliable railway sector.
The impact of R&D in the railway industry
Elemaster Group’s dedication to research and development is transforming railway safety and efficiency. With advanced integrated systems, IoT platforms, and AI-driven predictive maintenance, the company is helping operators reduce costs, improve operations, and build more resilient transport networks.
By continuously pushing the limits of innovation and compliance, Elemaster ensures that the railway industry keeps moving forward—safely, efficiently, and sustainably.