Secure IoT device development with Zephyr RTOS
We help device manufacturers build cyber-secure IoT controllers – from firmware development to cloud connectivity and user interfaces.
Device security
Cloud connectivity
Apps and portals
Zephyr OS results – delivered by Proekspert
In connected device manufacturing, every delay or misstep costs real money – or future flexibility. Zephyr OS unlocks hardware options and margin control, but securing scalable, compliant products requires more than integration – it demands field-proven engineering.
Proekspert delivers beyond standard integration: we build custom networking stacks, universal firmware, and resource-optimized solutions where Zephyr’s default features fall short. Clients trust us to turn complex hardware and software challenges into secure, connected, future-ready products – without costly detours.
Why trust Proekspert?
For over 20 years, we’ve helped leading device manufacturers ship secure, connected products – on time, on budget, and at scale. Companies like Danfoss and Stiebel Eltron trust us to solve complex hardware and software integration – so you can focus on growing your business.
End result: Secure, compliant, connected devices built on Zephyr OS – ready to scale, on hardware that fits your business model.
Partnerships
Proekspert’s Zephyr RTOS development and consulting services
We help device manufacturers accelerate secure IoT product development with hands-on Zephyr RTOS expertise and a focus on robust, production-ready implementation. Our approach combines best-practice security, seamless hardware integration, and proven building blocks – delivering faster time-to-market for your connected products.
Zephyr RTOS building blocks and service areas
Platform readiness and board support
- Zephyr RTOS enablement on industry-standard MCUs: ARM® Cortex®-M families including STM32, NXP i.MX, Nordic nRF, and more
- Custom board support packages (BSP), device tree configuration, and hardware enablement tailored to your specific device
- Secure boot configuration, trusted execution environments (TrustZone), and custom board integration
- Support for EU CRA compliance and IEC 62443 security standards
Hardware-backed security
- Integration of secure elements (e.g., STSAFE, ATECC608) and crypto modules to protect credentials and sensitive operations
- Middleware porting, secure key management, and architectures that keep private keys protected in hardware at all times
- Expert guidance on selecting and implementing the best-fit security ICs for your application
- Device identity management for secure onboarding and provisioning, and zero-touch deployment
IoT cloud connectivity
- Robust device-to-cloud connections via Azure IoT Hub, AWS IoT Core, Golioth, LwM2M, MQTT, and CoAP (learn more about our cloud connectivity expertise)
- PKI-based authentication, encrypted communications, and Zephyr RTOS native TLS with hardware trust anchors
Secure boot and OTA firmware updates
- MCUboot-based secure boot pipeline configuration and adaptation for your hardware
- End-to-end firmware security ensuring devices only run verified, trusted software
- OTA (over-the-air) firmware update capability for safe, remote deployments across your device fleet
User interface development
- Embedded UI design for intuitive, reliable device operation
- Integration of display drivers, input handling, and LVGL graphics library for a modern end-user experience
Portability and reference implementations
- Ready-to-port reference designs combining common MCU platforms, secure elements, and Zephyr RTOS features
- Accelerated delivery from concept to MVP, easier compliance preparation, and faster certification milestones
Case study
Local networking for next-gen EV chargers on Zephyr RTOS
A European EV charger manufacturer needed robust local networking on Zephyr RTOS, supporting device-to-device interconnectivity, flexible routing, and integration with Wi-Fi and modem hardware. Out-of-the-box Zephyr networking and off-the-shelf workarounds proved insufficient for scalable, reliable charger clusters.
Our solution
- Engineered a custom Zephyr RTOS networking stack (IPv4 routing and NAT) optimized for NXP hardware with FlexRAM
- Delivered universal firmware where each charger auto-configures as router or node, eliminating the need for unique images
- Integrated plug-and-play connectivity for cable, Wi-Fi (Nordic nRF), and modem links, including custom stack extensions for full hardware support
Result
A production-ready, scalable EV charger platform with reliable, self-organizing local networks – validated in lab, ready for rollout, and designed for fast integration of payments, diagnostics, and smart grid features.
Ready to build your secure IoT device with Zephyr RTOS?
Get expert Zephyr RTOS consulting from the start. We offer a detailed feasibility assessment and a step-by-step development or migration plan tailored to your IoT controller or connected product. Let us discuss your project goals and how our embedded engineering team can help.
Contact us for a discovery call or a tailored project estimate.
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Jukka Antero Halttunen
Proekspert AS
Tallinn headquarters
Sõpruse pst 157
13417 Tallinn
Estonia (EU)
Reg code 10331577
VAT no EE100185388
© 2026, Proekspert AS
